Non-aqueous electrolyte battery, method of manufacturing non-aqueous electrolyte battery, insulating material, method of manufacturing insulating material, battery pack, electronic device, electromotive vehicle, power storage apparatus, and electric power system

ABSTRACT

A non-aqueous electrolyte battery has a positive electrode, a negative electrode, an insulating layer present between the positive electrode and the negative electrode, and an electrolytic solution holding layer that composes the insulating layer and includes an electrolytic solution and a porous polymer compound, in which the electrolytic solution is held in the pores in the porous polymer compound and swells the porous polymer compound, the material of the porous polymer compound includes a vinylidene fluoride polymer, the vinylidene fluoride polymer is a vinylidene fluoride homopolymer or a copolymer including a vinylidene fluoride monomer unit and a hexafluoropropylene monomer unit, the mass composition ratio of the monomer units of the vinylidene fluoride polymer, or vinylidene fluoride monomer units:hexafluoropropylene monomer units, is 100:0 to 95:5, and the weight average molecular weight of the vinylidene fluoride polymer is 500,000 or more to less than 1.5 million.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority to Japanese Patent ApplicationNo. 2011-187781 filed on Aug. 30, 2011, and contains subject matterrelated to Japanese Patent Application No. 2010-192227 filed on Aug. 30,3010, the disclosures of which are incorporated herein by reference.

BACKGROUND

The present technology relates to a non-aqueous electrolyte battery, amethod of manufacturing the non-aqueous electrolyte battery, aninsulating material, a method of manufacturing the insulating material,a battery pack, an electronic device, an electromotive vehicle, a powerstorage apparatus, and an electric power system. More specifically, thetechnology relates to a non-aqueous electrolyte battery having a porouspolymer compound holding an electrolytic solution, a method ofmanufacturing the non-aqueous electrolyte battery, an insulatingmaterial, a method of manufacturing the insulating material, a batterypack, an electronic device, an electromotive vehicle, a power storageapparatus, and an electric power system.

A lithium ion secondary battery generally has a configuration in whichcarbon, a lithium-transition metal complex oxide, and a mixture ofcarbonate esters are used for the negative electrode, the positiveelectrode, and an electrolytic solution, respectively. Since carbonateester used for the electrolytic solution is not easily oxidized orreduced by water or other organic solvents, and can obtain a highervoltage, the lithium ion secondary battery has a higher energy densityand a higher capacity than a nickel-hydrogen battery, which is anaqueous battery. Therefore, the lithium ion secondary battery is widelydistributed as a secondary battery for notebook-type personal computers,mobile phones, video cameras, and digital still cameras.

Since a laminate-type lithium ion secondary battery in which a laminatefilm, such as an aluminum laminate film, is used for an exterior has alight weight and a large energy density, which results from a largefraction of an active material in the battery, the laminate-type lithiumion secondary battery is widely used.

Since the laminate-type lithium ion secondary battery has a weakerstrength than a battery covered with a metal can, the voltage applied toa battery element becomes weak. Therefore, when the electrode isexpanded and shrunk due to repetition of charging and discharging of thebattery, there is a problem in that the inter-electrode distance betweenthe positive electrode and the negative electrode becomes uneven due tothe above fact, and thus the ion conductivity and the electric currentdensity become uneven, whereby the capacity is degraded.

With respect to this problem, a technology in which the inter-electrodedistance is kept constant by providing a resin having an adhering forcebetween the positive electrode and the negative electrode, anddegradation of the capacity due to repetition of charging anddischarging is suppressed has been suggested.

For example, Japanese Patent No. 4099969 describes a battery in which aporous resin is formed on the surface of an electrode by floating aporous endothermic insulating resin in the electrode on the surface ofthe electrode by spinodal decomposition or a micelle method.

SUMMARY

However, in a battery having a configuration in which a porous resinmanufactured using spinodal decomposition is disposed between theelectrodes, a polymer material having the optimal material kind andcomposition should be used as a material of the porous resin. That is,when a polymer material having the optimal material kind and compositionis not used as a material of the porous resin, since the optimalporosity is not obtained, the ion conductivity is degraded, and batterycharacteristics are degraded. In addition, since the adhesivenessbetween the electrodes is degraded, and the inter-electrode distancebecomes uneven due to repetition of charging and discharging, thecapacity is degraded due to repetition of charging and discharging.

Therefore, it is desirable to provide a non-aqueous electrolyte batteryin which degradation of the ion conductivity can be suppressed, anddegradation of the capacity due to repetition of charging anddischarging can be suppressed, a method of manufacturing the non-aqueouselectrolyte battery, an insulating material, a method of manufacturingthe insulating material, a battery pack, an electronic device, anelectromotive vehicle, a power storage apparatus, and an electric powersystem.

According to the technology, there is provided a non-aqueous electrolytebattery having a positive electrode, a negative electrode, an insulatinglayer present between the positive electrode and the negative electrode,and an electrolytic solution holding layer that composes the insulatinglayer and includes an electrolytic solution and a porous polymercompound, in which the electrolytic solution is held in the pores in theporous polymer compound and swells the porous polymer compound, thematerial of the porous polymer compound includes a vinylidene fluoridepolymer, the vinylidene fluoride polymer is a vinylidene fluoridehomopolymer or a copolymer including a vinylidene fluoride monomer unitand a hexafluoropropylene monomer unit, the mass composition ratio ofthe monomer units of the vinylidene fluoride polymer, or vinylidenefluoride monomer units:hexafluoropropylene monomer units, is 100:0 to95:5, and the weight average molecular weight of the vinylidene fluoridepolymer is 500,000 or more to less than 1.5 million.

The technology is a method of manufacturing a non-aqueous electrolytebattery in which a polymer material includes a vinylidene fluoridepolymer, the vinylidene fluoride polymer is a vinylidene fluoridehomopolymer or a copolymer including a vinylidene fluoride monomer unitand a hexafluoropropylene monomer unit, the mass composition ratio ofthe monomer units of the vinylidene fluoride polymer, or vinylidenefluoride monomer units:hexafluoropropylene monomer units, is 100:0 to95:5, and the weight average molecular weight of the vinylidene fluoridepolymer is 500,000 or more to less than 1.5 million, having a process inwhich a solution containing the polymer material dissolved in a firstsolvent composed of a polar organic solvent is coated on a porous basematerial, the coated porous base material is immersed in a secondsolvent, which is compatible with the first solvent and is a poorsolvent with respect to the polymer material, thereby forming a porouspolymer compound on the porous base material; a process in which anelectrode body having a positive electrode, a negative electrode, andthe porous base material on which the porous polymer compound is formed,in which the porous base material is present between the positiveelectrode and the negative electrode, is manufactured; and a process inwhich the electrode body is accommodated in an exterior body, anelectrolytic solution is injected into the exterior body, and then heatpressing is carried out.

The technology is an insulating material including a porous polymercompound, in which the porous polymer compound can hold an electrolyticsolution in the pores, and can be swollen by the electrolytic solution,the material of the porous polymer compound includes a vinylidenefluoride polymer, the vinylidene fluoride polymer is a vinylidenefluoride homopolymer or a copolymer including a vinylidene fluoridemonomer unit and a hexafluoropropylene monomer unit, the masscomposition ratio of the monomer units of the vinylidene fluoridepolymer, or vinylidene fluoride monomer units:hexafluoropropylenemonomer units, is 100:0 to 95:5, and the weight average molecular weightof the vinylidene fluoride polymer is 500,000 or more to less than 1.5million.

The technology is a method of manufacturing an insulating materialincluding a porous polymer compound, having a process in which asolution containing a polymer material dissolved in a first solventcomposed of a polar organic solvent is coated on a base material, thebase material coated with the solution is immersed in a second solvent,which is compatible with the first solvent and is a poor solvent withrespect to the polymer material, thereby forming the porous polymercompound, in which the polymer material includes a vinylidene fluoridepolymer, the vinylidene fluoride polymer is a vinylidene fluoridehomopolymer or a copolymer including a vinylidene fluoride monomer unitand a hexafluoropropylene monomer unit, the mass composition ratio ofthe monomer units of the vinylidene fluoride polymer, or vinylidenefluoride monomer units:hexafluoropropylene monomer units, is 100:0 to95:5, and the weight average molecular weight of the vinylidene fluoridepolymer is 500,000 or more to less than 1.5 million.

The battery pack, the electronic device, the electromotive vehicle, thepower storage apparatus, and the electric power system of the technologyhave the above non-aqueous electrolyte battery.

In the technology, a vinylidene fluoride polymer having a masscomposition ratio, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, of 100:0 to 95:5, and a weightaverage molecular weight of 500,000 or more to less than 1.5 million isused as the material of the porous polymer compound. Thereby, favorableion conductivity, and favorable adhesiveness between the positiveelectrode and the negative electrode can be obtained.

According to the technology, degradation of the ion conductivity can besuppressed, and degradation of the capacity due to repetition ofcharging and discharging can be suppressed.

Additional features and advantages are described herein, and will beapparent from the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an exploded perspective view showing an example of theconfiguration of the non-aqueous electrolyte battery according to theembodiment of the technology.

FIG. 2 is a cross-section view of a wound electrode body taken along theline I-I in FIG. 1.

FIG. 3A is a perspective view showing the appearance of the non-aqueouselectrolyte battery of the technology. FIG. 3B is a perspective explodedview showing the configuration of the non-aqueous electrolyte battery.FIG. 3C is a perspective view showing the configuration of the bottomsurface of the non-aqueous electrolyte battery shown in FIG. 3A.

FIG. 4A is a perspective view showing an example of the configuration ofthe positive electrode. FIG. 4B is a perspective view showing an exampleof the configuration of the positive electrode. FIG. 4C is a perspectiveview showing an example of the configuration of the positive electrode.FIG. 4D is a perspective view showing an example of the configuration ofthe positive electrode.

FIG. 5A is a perspective view showing an example of the configuration ofthe battery element of the technology. FIG. 5B is a cross-sectional viewshowing an example of the configuration of the battery element of thetechnology.

FIG. 6 is a cross-sectional view showing the VI-VI cross section of thenon-aqueous electrolyte battery in FIG. 3A.

FIG. 7 is a cross-sectional view showing an example of the configurationof the laminate film.

FIGS. 8A to 8E are process charts showing the process of folding into aU shape the electrode tab of the battery element of the technology.

FIGS. 9A to 9E are process charts showing the process of folding into aU shape the electrode tab of the battery element of the technology.

FIGS. 10A to 10C are process charts showing the process of connectingthe electrode tab and the electrode lead of the battery element of thetechnology.

FIGS. 11A to 11D are process charts showing the process of folding theelectrode lead connected to the battery element of the technology.

FIG. 12A is a perspective view showing the appearance of the non-aqueouselectrolyte battery of the technology. FIG. 12B is a perspectiveexploded view showing the configuration of the non-aqueous electrolytebattery. FIG. 12C is a perspective view showing the configuration of thebottom surface of the non-aqueous electrolyte battery shown in FIG. 12A.

FIG. 13A is a perspective view showing an example of the configurationof the battery element of the technology. FIG. 13B is a cross-sectionalview showing an example of the configuration of the battery element ofthe technology.

FIG. 14A is a cross-sectional view showing the XIVA-XIVA cross sectionof the non-aqueous electrolyte battery in FIG. 12A. FIG. 14B is across-sectional view showing the XIVB-XIVB cross section of thenon-aqueous electrolyte battery in FIG. 12A.

FIG. 15 is a block diagram showing an example of the configuration ofthe battery pack according to the embodiment of the technology.

FIG. 16 is a schematic view showing an example in which the non-aqueouselectrolyte battery of the technology is applied to a house powerstorage system.

FIG. 17 is a schematic view schematically showing an example of theconfiguration of a hybrid vehicle in which a series hybrid system towhich the technology is applied is employed.

FIG. 18 is a SEM photograph of a portion of the surface of theinsulating layer of Sample 1-4 after heat pressing.

FIG. 19 is a SEM photograph of a portion of the surface of theinsulating layer of Sample 1-10 after heat pressing.

FIG. 20 is a SEM photograph of a portion of the surface of theinsulating layer of Sample 1-4 after heat pressing which is differentfrom the portion shown in FIG. 18.

FIG. 21 is a SEM photograph of a portion of the surface of theinsulating layer of Sample 1-10 after heat pressing which is differentfrom the portion shown in FIG. 19.

DETAILED DESCRIPTION

Embodiments of the present application will be described below in detailwith reference to the drawings.

Hereinafter, the embodiments of the present technology will be describedwith reference to the drawings. Meanwhile, the description will be madein the following order.

1. A first embodiment (a first example of the non-aqueous electrolytebattery)

2. A second embodiment (a second example of the non-aqueous electrolytebattery)

3. A third embodiment (a third example of the non-aqueous electrolytebattery)

4. A fourth embodiment (an example of a battery pack in which thenon-aqueous electrolyte battery is used)

5. A fifth embodiment (an example of an electric storage system and thelike in which the non-aqueous electrolyte battery is used)

6. Other embodiment (an example of variation)

1. First Embodiment

(Configuration of the Non-Aqueous Electrolyte Battery)

The non-aqueous electrolyte battery according to the first embodiment ofthe technology will be described. FIG. 1 shows the exploded perspectiveconfiguration of the non-aqueous electrolyte battery according to thefirst embodiment. FIG. 2 shows the enlarged cross-section of a woundelectrode body 30, which is taken along the line I-I in FIG. 1.

The non-aqueous electrolyte battery mainly accommodates the woundelectrode body 30, to which a positive electrode lead 31 and a negativeelectrode lead 32 are attached, in a film-shaped exterior member 40.This battery structure in which the film-shaped exterior member 40 isused is called a laminate film type.

The positive electrode 31 and the negative electrode 32 are drawn out inthe same direction, for example, from the inside of the exterior member40 to the outside. The positive electrode lead 31 is composed of, forexample, a metallic material, such as aluminum, and the negativeelectrode lead 32 is composed of, for example, a metallic material, suchas copper, nickel, and stainless steel. These metallic materials have,for example, a thin plate shape or a netlike shape.

The exterior member 40 is composed of an aluminum laminate film in whicha nylon film, an aluminum foil, and a polyethylene film are bonded inthis order. The exterior member 40 has a configuration in which, forexample, two sheets of rectangular aluminum laminate films are thermallyfused or mutually adhered using an adhesive at the outer circumferentialportions so that the polyethylene film surfaces the wound electrode body30.

Adhering films 41 are inserted between the exterior member 40 and thepositive electrode 31 and the negative electrode 32 in order to preventintrusion of external air. The adhering film 41 is composed of amaterial having adhesiveness with respect to the positive electrode lead31 and the negative electrode lead 32. Examples of such a materialinclude polyolefin resins, such as polyethylene, polypropylene, modifiedpolyethylene, and modified polypropylene.

Meanwhile, instead of the aluminum laminate film, the exterior member 40may be composed of a laminate film having another laminate structure, ormay be composed of a polymer film, such as polypropylene, and a metalfilm.

FIG. 2 shows the cross-sectional configuration of the wound electrodebody 30 taken along the line I-I in FIG. 1. The wound electrode body 30has a positive electrode 33 and a negative electrode 34 laminated andwound through an insulating layer 39, which is composed of a separator35 and an electrolytic solution holding layer 36, and the outermostcircumferential portion is protected with a protective tape 37. In thewound electrode body 30, the electrolytic solution holding layer 36 isformed on both surfaces of the separator 35, and the separator 35 andthe positive electrode 33, and the separator 35 and the negativeelectrode 34 are adhered through the electrolytic solution holding layer36, respectively. In addition, the positive electrode 33 and thenegative electrode 34 are adhered through the insulating layer 39.Provision of the insulating layer 39 between the positive electrode 33and the negative electrode 34 increases the adhesiveness between thepositive electrode 33 and the negative electrode 34 so as to suppressthe inter-electrode distance from becoming uneven due to repetition ofcharging and discharging. Meanwhile, the electrolytic solution holdinglayer 36 may be formed on only one surface of the separator 35.

(Positive Electrode)

The positive electrode 33, for example, has positive electrode activematerial layers 33B provided at both surfaces of a positive electrodecollector 33A having a pair of surfaces. However, the positive electrodeactive material layer 33B may be provided on only one surface of thepositive electrode collector 33A.

The positive electrode collector 33A is composed of, for example, ametallic material, such as aluminum, nickel, and stainless steel.

The positive electrode active material layer 33B includes one or two ormore positive electrode materials that can absorb and discharge lithiumas a positive electrode active material, and may include othermaterials, such as a bonding agent and a conducting agent, according tonecessity.

(Positive Electrode Material)

Appropriate examples of the positive electrode materials that can absorband discharge lithium include lithium oxides, lithium phosphate, lithiumsulfate, and lithium-containing compounds, such as interlayer compoundsand the like including lithium, and the materials may be used incombination of two or more kinds Lithium-containing compounds includinglithium, transition metal elements, and oxygen (O) are preferred toincrease the energy density. Examples of the lithium-containingcompounds include lithium complex oxides having a bedded salt-typestructure represented by the following formula (1), lithium complexphosphates having an olivine-type structure represented by the followingformula (2), and the like. The lithium-containing compounds preferablyinclude at least one from a group composed of cobalt (Co), nickel (Ni),manganese (Mn), and iron (Fe) as the transition metal elements. Examplesof the lithium-containing compounds lithium complex oxides having abedded salt-type structure represented by the following formula (3),(4), or (5), lithium complex oxides having a spinel-type structurerepresented by the following formula (6), lithium complex phosphatehaving an olivine-type structure represented by the following formula(7), and the like. Specific preferred examples include lithium complexoxides, such as lithium cobaltate, lithium nickelate, and solidsolutions thereof {Li(Ni_(x)Co_(y)Mn_(z))O₂ (the values of x, y, and zare 0<x<1, 0<y<1, 0≦z<1, and x+y+z=1), Li(Ni_(x)Co_(y)Al_(z))O₂ (thevalues of x, y, and z are 0<x<1, 0<y<1, 0≦z<1, and x+y+z=1), and thelike}, and manganese spinel (LiMn₂O₄) and solid solutions thereof{Li(Mn_(2-v)Ni_(v))O₄ (the values of v is v<2)}, and phosphate compoundshaving an olivine structure, such as lithium iron phosphate (LiFePO₄),Li_(x)Fe_(1-y)M2_(y)PO₄ (in the formula, “M2” represents at least onefrom a group composed of manganese (Mn), nickel (Ni), cobalt (Co), zinc(Zn), and magnesium (Mg). “x” is a value in a range of 0.9≦x≦1.1.). Thisis because a high energy density can be obtained.

Li_(p)Ni_((1-q-r))Mn_(q)M1_(r)O_((2-y))X_(z)   (1)

(in the formula, “M1” represents at least one of elements selected fromGroups 2 to 15 excluding nickel (Ni) and manganese (Mn). “x” representsat least one of Group 16 elements and Group 17 elements other thanoxygen (O). “p”, “q”, “y” and “z” are values in ranges of 0≦p≦1.5,0≦q≦1.0, 0≦r≦1.0, −0.10≦y≦0.20, and 0≦z≦0.2.).

Li_(a)M2_(b)PO₄   (2)

(in the formula, “M2” represents at least one of elements selected fromGroups 2 to 15. “a” and “b” are values in ranges of 0≦a≦2.0 and0.5≦b≦2.0.)

Li_(f)Mn_((1-g-h))Ni_(g)M3_(h)O_((2-j))F_(k)   (3)

(in the formula, “M3” represents at least one from a group composed ofcobalt (Co), magnesium (Mg), aluminum (Al), boron (B), titanium (Ti),vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc (Zn),zirconium (Zr), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr)and tungsten (W). “f”, “g”, “h”, “j”, and “k” are values in ranges of0.8≦f≦1.2, 0≦g≦0.5, 0≦h≦0.5, g+h<1, −0.1≦j≦0.2, and 0≦k≦0.1. Meanwhile,the composition of lithium varies with the charging and dischargingstate, and the value of “f” represents a value in a fully dischargedstate.)

Li_(m)Ni_((1-n))M4_(n)O_((2-p))F_(q)   (4)

(in the formula, “M4” represents at least one from a group composed ofcobalt (Co), manganese (Mn), magnesium (Mg), aluminum (Al), boron (B),titanium (Ti), vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc(Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr) andtungsten (W). “m”, “n”, “p”, and “q” are values in ranges of 0.8≦m≦1.2,0.005≦n≦0.5, −0.1≦p≦0.2, and 0≦q≦0.1. Meanwhile, the composition oflithium varies with the charging and discharging state, and the value of“m” represents a value in a fully discharged state.)

Li_(r)Co_((1-s))M5_(s)O_((2-t))F_(u)   (5)

(in the formula, “M5” represents at least one from a group composed ofnickel (Ni), manganese (Mn), magnesium (Mg), aluminum (Al), boron (B),titanium (Ti), vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc(Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). “r”, “s”, “t”, and “u” are values in ranges of 0.8≦r≦1.2,0≦s≦0.5, −0.1≦t≦0.2, and 0≦u≦0.1. Meanwhile, the composition of lithiumvaries with the charging and discharging state, and the value of “r”represents a value in a fully discharged state.)

Li_(v)Mn_(2-w)M6_(w)O_(x)F_(y)   (6)

(in the formula, “M6” represents at least one from a group composed ofcobalt (Co), nickel (Ni), magnesium (Mg), aluminum (Al), boron (B),titanium (Ti), vanadium (V), chromium (Cr), iron (Fe), copper (Cu), zinc(Zn), molybdenum (Mo), tin (Sn), calcium (Ca), strontium (Sr), andtungsten (W). “v”, “w”, “x”, and “y” are values in ranges of 0.9≦v≦1.1,0≦w≦0.6, 3.7≦x≦4.1, and 0≦y≦0.1. Meanwhile, the composition of lithiumvaries with the charging and discharging state, and the value of “v”represents a value in a fully discharged state.)

Li_(z)M7PO₄   (7)

(in the formula, “M7” represents at least one from a group composed ofcobalt (Co), manganese (Mn), iron (Fe), nickel (Ni), magnesium (Mg),aluminum (Al), boron (B), titanium (Ti), vanadium (V), niobium (Nb),copper (Cu), zinc (Zn), molybdenum (Mo), calcium (Ca), strontium (Sr),tungsten (W), and zirconium (Zr). “z” is a value in a range of0.9≦z≦1.1. Meanwhile, the composition of lithium varies with thecharging and discharging state, and the value of “z” represents a valuein a fully discharged state.) In addition, examples of the positiveelectrode materials that can absorb and discharge lithium also includeoxides, such as titanium oxides, vanadium oxide, and manganese dioxide;disulfides, such as iron disulfide, titanium disulfide, and molybdenumsulfide; conductive polymers, such as sulfur, polyaniline, andpolythiophene; and the like.

Clearly, the positive electrode materials that can absorb and dischargelithium may be materials other than the exemplified materials.

Examples of the bonding agent include synthetic rubber, such as styrenebutadiene-based rubber, fluorine-based rubber, and ethylene propylenediene; and polymer materials, such as polyvinylidene fluoride. Thesematerials may be used singly or in combination of a plurality of kindsAmong them, polyvinylidene fluoride is preferred.

Examples of the conducting agent include carbon materials, such asgraphite and carbon black. These materials may be used singly or incombination of a plurality of kinds

(Negative Electrode)

The negative electrode 34, for example, has negative electrode activematerial layers 34B provided at both surfaces of a negative electrodecollector 34A having a pair of surfaces. However, the negative electrodeactive material layer 34B may be provided on only one surface of thenegative electrode collector 34A.

The negative electrode collector 34A is composed of, for example, ametallic material, such as copper, nickel, and stainless steel.

The negative electrode active material layer 34B includes one or two ormore negative electrode materials that can absorb and discharge lithiumas a negative electrode active material, and may include othermaterials, such as a bonding agent and a conducting agent, according tonecessity. Meanwhile, the same bonding agent and conducting agent asdescribed in the positive electrode section respectively can be used asthe bonding agent and the conducting agent.

The negative electrode materials that can absorb and discharge lithiumare, for example, carbon materials. Examples of the carbon materialsinclude easily-graphitizable carbon, non-graphitizable carbon in whichthe plane separation of the (002) plane is 0.37 nm or more, graphite inwhich the plane separation of the (002) plane is 0.34 nm or less, andthe like. More specific examples include pyrolytic carbon, cokes,glass-shaped carbon fibers, fired organic polymer compounds, activatedcharcoal, carbon blacks, and the like. Among them, the cokes includepitch coke, needle coke, petroleum coke, and the like. The fired organicpolymer compound refers to a phenol resin, a furan resin, and the likewhich are fired at an appropriate temperature so as to be carbonized.Carbon materials are preferred since the change of the crystal structureaccording to absorption and discharging of lithium is extremely small,and therefore a high energy density is obtained, and excellent cyclecharacteristics are obtained, and, furthermore, carbon materials act asa conducting agent. Meanwhile, the forms of carbon materials may befibrous, spherical, granular, and scale-like.

Examples of the negative electrode materials that can absorb anddischarge lithium other than the above carbon materials includematerials that can absorb and discharge lithium, and have at least oneof metal elements and semimetal elements as a constituent element. Thisis because a high energy density can be obtained. Such negativeelectrode materials may be a single body, alloy, or compound of metalelements or semimetal elements, or may be a substance having the phasesof one or two or more of metal elements or semimetal elements at leastat some parts. Meanwhile, the “alloy” in the technology includes notonly substances composed of two or more of metal components but alsosubstances including one or more of metal elements and one or more ofsemimetal elements. In addition, the “alloy” may also include nonmetalelements. In the structure of the alloy, sometimes, solid solutions,eutectic (eutectic mixtures), intermetallic compounds, or two or morekinds thereof may coexist.

Examples of the metal elements or semimetal elements include metalelements or semimetal elements that can form alloys with lithium.Specific examples include magnesium (Mg), boron (B), aluminum (Al),gallium (Ga), indium (In), silicon (Si), germanium (Ge), tin (Sn), lead(Pb), bismuth (Bi), cadmium (Cd), silver (Ag), zinc (Zn), hafnium (Hf),zirconium (Zr), yttrium (Y), palladium (Pd), platinum (Pt), and thelike. Among them, at least one of silicon and tin is preferred, andsilicon is more preferred. This is because the ability of absorbing anddischarging lithium is large, and therefore a high energy density can beobtained.

Examples of the negative electrode materials having at least one ofsilicon and tin include a single body, alloys, or compounds of silicon,a single body, alloys, or compounds of tin, and materials having thephases of one or two or more of silicon and tin at least at some parts.

Examples of silicon alloys include alloys including, in addition tosilicon, at least one from a group composed of tin (Sn), nickel (Ni),copper (Cu), iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium(In), silver (Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony(Sb) and chromium (Cr) as the second constituent element. Examples oftin alloys include alloys including, in addition to tin (Sn), at leastone from a group composed of silicon (Si), nickel (Ni), copper (Cu),iron (Fe), cobalt (Co), manganese (Mn), zinc (Zn), indium (In), silver(Ag), titanium (Ti), germanium (Ge), bismuth (Bi), antimony (Sb) andchromium (Cr) as the second constituent element.

Examples of tin compounds or silicon compounds include compoundsincluding oxygen (O) or carbon (C), and may also include, in addition totin (Sn) or silicon (Si), the above second constituent element.

Particularly, preferable examples of the negative electrode materialsincluding at least one of silicon (Si) and tin (Sn) include materialsincluding tin (Sn) as the first constituent element and, in addition tothe tin, the second constituent element and the third constituentelement. Clearly, these negative electrode materials may be usedtogether with the above negative electrode materials. The secondconstituent element is at least one from a group composed of cobalt(Co), iron (Fe), magnesium (Mg), titanium (Ti), vanadium (V), chromium(Cr), manganese (Mn), nickel (Ni), copper (Cu), zinc (Zn), gallium (Ga),zirconium (Zr), niobium (Nb), molybdenum (Mo), silver (Ag), indium (In),cerium (Ce), hafnium (Hf), tantalum (Ta), tungsten (W), bismuth (Bi) andsilicon (Si). The third constituent element is at least one from a groupcomposed of boron (B), carbon (C), aluminum (Al), and phosphorous (P).This is because inclusion of the second constituent element and thethird constituent element improves the cycle characteristics.

Among them, CoSnC-containing materials including tin (Sn), cobalt (Co),and carbon (C) as the constituent elements, in which the content ofcarbon (C) is in a range of 9.9% by mass or more to 29.7% by mass orless, and the ratio of cobalt (Co) to the sum of tin (Sn) and cobalt(Co) (Co/(Sn+Co)) is in a range of 30% by mass or more to 70% by mass orless, are preferred. This is because, in these composition ranges, ahigh energy density can be obtained, and excellent cycle characteristicscan be obtained.

The SnCoC-containing materials may further include other constituentelements according to necessity. Preferable examples of the otherconstituent elements include silicon (Si), iron (Fe), nickel (Ni),chromium (Cr), indium (In), niobium (Nb), germanium (Ge), titanium (Ti),molybdenum (Mo), aluminum (Al), phosphorous (P), gallium (Ga), bismuth(Bi), and the like, and the SnCoC-containing materials may include twoor more of them. This is because the capacity characteristics or cyclecharacteristics are further improved.

Meanwhile, the SnCoC-containing materials have a phase including tin(Sn), cobalt (Co), and carbon (C), and the phase preferably has a lowcrystallinity or amorphous structure. In addition, in theSnCoC-containing materials, it is preferable that at least some ofcarbon, which is a constituent element, bonds with a metal element or asemimetal element, which is another constituent element. This isbecause, although degradation of the cycle characteristics is consideredto be caused by agglomeration or crystallization of tin (Sn) and thelike, bonding of carbon with other elements suppresses the agglomerationor crystallization.

Examples of a measuring method by which the bonding state of theelements is investigated include X-ray photoelectron spectroscopy (XPS)and the like. In XPS, a carbon 1s (C1s) peak appears at 284.5 eV forgraphite in an apparatus that is energy-calibrated so that a gold atom4f (Au4f) peak is obtained at 84.0 eV. In addition, the carbon 1s peakappears at 284.8 eV for surface-contaminated carbon. In contrast tothis, when the charge density of carbon element is increased, forexample, when carbon is bonded with a metal element or semimetalelement, the C1s peak appears in a range lower than 284.5 eV. That is,when the peak of the synthetic wave of C1s obtained for theSnCoC-containing material appears in a range lower than 284.5 eV, atleast some of the carbon included in the SnCoC-containing material isbonded with a metal element or semimetal element, which is the othercomponent element.

Meanwhile, in XPS measurement, for example, the C1s peak is used for thecorrection of the energy axis of a spectrum. In general, sincesurface-contaminated carbon is present on the surface, the C1s peak ofthe surface-contaminated carbon is set to 284.8 eV, which is used as theenergy criterion. In XPS measurement, since the waveform of the C1s peakis obtained as a form including the peak of the surface-contaminatedcarbon and the peak of carbon in the SnCoC-containing material, the peakof the surface-contaminated carbon and the peak of carbon in theSnCoC-containing material are separated by an analysis using, forexample, commercially available software. In waveform analyses, thelocation of the main peak present in the minimum bonding energy side isused as the energy criterion (284.8 eV).

In addition, examples of the negative electrode materials that canabsorb and discharge lithium also include metal oxides, polymer oxides,and the like that can absorb and discharge lithium. Examples of themetal oxides include iron oxide, ruthenium oxide, molybdenum oxide, andthe like, and examples of the polymer oxides include polyacetylene,polyaniline, polypyrrole, and the like.

Furthermore, the negative electrode materials that can absorb anddischarge lithium may also be materials including elements that formcomplex oxides with lithium, such as titanium.

Clearly, metallic lithium may be used, precipitated, and dissolved asthe negative electrode active material. It is also possible toprecipitate and dissolve magnesium or aluminum other than lithium.

The negative electrode active material layer 34B may be formed by anyof, for example, a gas phase method, a liquid phase method, flamegunning, a firing method, and coating, or may be formed by a combinationof two or more of them. Meanwhile, examples of the gas phase methodinclude a physical deposition method and a chemical deposition method,and specific examples include a vacuum deposition method, sputteringmethod, an ion plating method, a laser application method, a thermalchemical vapor deposition (CVD) method, and a plasma chemical vapordeposition method, and the like. Well-known methods, such aselectroplating and electroless plating, can be used as the liquid phasemethod. Examples of the firing method include a method in which agranular negative electrode active material is mixed with a bondingagent and the like, dispersed in a solvent, coated, and then a thermaltreatment is carried out at a temperature higher than the melting pointsof the bonding agent and the like. Well-known methods can be used as thefiring method, and examples thereof include an atmospheric firingmethod, a reactive firing method, and a hot press firing method.

When metallic lithium is used as the negative electrode active material,the negative electrode active material layer 34B may be already presentfrom the moment of assembling, but may not be present at the moment ofassembling and be composed of lithium metal that is precipitated duringcharging. In addition, the negative electrode collector 34A may not beincluded by using the negative electrode active material layer 34B as acollector.

(Insulating Layer)

The insulating layer 39 is composed of the separator 35 and theelectrolytic solution holding layer 36 formed on at least one surface ofthe separator 35. Meanwhile, the insulating layer 39 may be composed ofonly the electrolytic solution holding layer 36 without the separator35.

(Separator)

The separator 35 is a porous material that separates the positiveelectrode 33 and the negative electrode 34, prevents short-circuiting ofelectric currents caused by the contact of both electrodes, and passeslithium ions. The separator 35 is composed of a porous film composed ofa polyolefin-based resin, such as polyethylene and polypropylene, aporous film composed of a ceramic, or the like. The separator may be alaminate of two or more of the above porous films. An electrolyticsolution is impregnated in the separator 35.

(Electrolytic Solution Holding Layer)

The electrolytic solution holding layer 36 includes a porous polymercompound and an electrolytic solution. In the electrolytic solutionholding layer 36, the electrolytic solution is held in pores in theporous polymer compound and swells the porous polymer compound.Meanwhile, the electrolytic solution holding layer 36 may have, solelyor together with the separator 35, functions of separating the positiveelectrode 33 and the negative electrode 34, preventing short-circuitingof electric currents caused by the contact of both electrodes, andpassing lithium ions.

In the electrolytic solution holding layer 36, a polymer material havingan optimal material kind and composition is used as the material of theporous polymer compound. Thereby, the porous polymer compound beingexcessively swollen during heat pressing in a battery-manufacturingprocess such that the porous structure is collapsed, and the pores areclosed, is suppressed. In addition, since the permeability is optimallyadjusted in the electrolytic solution holding layer 36, degradation ofthe ion conductivity is suppressed, and thus degradation of the batterycharacteristics is suppressed. In addition, since adhesiveness betweenthe positive electrode and the negative electrode can be improved byusing a polymer material having an optimal material kind and compositionas a material of the porous polymer compound, it is possible to suppressthe inter-electrode distance from becoming uneven due to repetition ofcharging and discharging.

The porous polymer compound is formed, for example, in the followingmanner. That is, firstly, a solution containing a polymer materialdissolved in a first solvent composed of a polar organic solvent, suchas N-methyl-2-pyrrolidone, γ-butyrolactone, N,N-dimethylacetamide, andN,N-dimethyl sulfoxide, is prepared, and the solution is coated on theseparator 35. Next, the separator 35 coated with the solution isimmersed in a second solvent which is compatible with the polar organicsolvent, such as water, ethyl alcohol, and propyl alcohol, and is a poorsolvent with respect to the polymer material. At this time, solventexchange occurs, and phase separation accompanying spinodaldecomposition occurs so that the polymer material can form a porousstructure. After that, the separator is dried so that a porous polymercompound having a porous structure can be obtained. Meanwhile, theelectrolytic solution holding layer 36 is formed by impregnating theelectrolytic solution in the porous polymer compound.

N-methyl-2-pyrrolidone is preferred as the first solvent. This isbecause the solubility is not degraded, and a uniform solution can beeasily prepared even when a vinylidene fluoride polymer, which will bedescribed below and has hexafluoropropylene monomer units in a masscomposition ratio of 5% or less, is used as the polymer material.

Preferable examples of the area density of the porous polymer compoundformed on the separator 35 are 0.1 mg/cm² or more to 10 mg/cm² or less.This is because, when the area density of the porous polymer compound issmaller than 0.1 mg/cm², it becomes difficult to develop a protectioneffect with respect to an oxidative decomposition reaction. This isbecause, when the area density of the porous polymer compound is largerthan 10 mg/cm², the length of the ion conduction path is extended by anincrease in the inter-electrode distance such that the energy densitytends to be degraded.

Vinylidene fluoride polymers including vinylidene fluoride monomer unitscan be used as the polymer material. Such vinylidene fluoride polymersinclude vinylidene fluoride homopolymers, a two-element copolymer ofvinylidene fluoride-hexafluoropropylene, a three-element copolymer ofvinylidene fluoride-hexafluoropropylene-chlorotrifluoroethylene, and thelike. Meanwhile, one or two or more of other polymer materials may beused together with the vinylidene fluoride copolymer.

Polymers having vinylidene fluoride monomer units andhexafluoropropylene monomer units in a mass composition ratio, orvinylidene fluoride monomer units:hexafluoropropylene monomer units, ina range of 100:0 to 95:5 is used as the vinylidene fluoride polymer.That is, vinylidene fluoride copolymers having vinylidene fluoridemonomer units and hexafluoropropylene monomer units in a masscomposition ratio of 5% or less can be used. When the mass compositionratio of the vinylidene fluoride monomer units and thehexafluoropropylene monomer units is outside the range of 100:0 to 95:5,that is, when the mass composition ratio of the hexafluoropropylenemonomer units exceeds 5%, the polymer compound becomes liable to swell,and the pore structure of the porous polymer compound is collapsedduring heat pressing in a battery-manufacturing process such that thepores are closed, the air permeability is increased, and the ionconductivity is degraded, whereby the battery characteristics aredegraded.

The weight average molecular weight of the vinylidene fluoride polymeris preferably 500,000 or more, and more preferably 750,000 or more. Inthe laminate film-type battery, it is important to keep theinter-electrode distance between the positive electrode and the negativeelectrode constant so as to maintain a favorable ion conductivity. Fromthe viewpoint of maintaining the inter-electrode distance constant, itis important to strongly bond the positive electrode 33 and the negativeelectrode 34 through the insulating layer 39. Therefore, the weightaverage molecular weight of the vinylidene fluoride polymer ispreferably 500,000 or more, and more preferably 750,000 or more since afavorable adhesiveness between the electrodes can be secured. Inaddition, the weight average molecular weight of the vinylidene fluoridepolymer is preferably less than 1.5 million, more preferably 1.2 millionor less, and further preferably 1 million or less from the standpoint ofeasy manufacturing.

Meanwhile, the weight average molecular weight is measured by gelpermeation chromatography (GPC) and polystyrene conversion using ameasurement solvent of N-methyl-2-pyrrolidone.

The air permeability of the porous polymer compound is preferably 500seconds/100 cc or less, and more preferably 300 seconds/100 cc or lesssince a favorable ion conductivity can be secured. In addition, thelower limit of the air permeability becomes a numeric value larger than0 second/100 cc when the physical structure of the insulating layer 39is taken into consideration.

The electrolytic solution holding layer 36 may contain inorganicparticles in addition to the porous polymer compound and theelectrolytic solution. The inorganic particles being contained in theelectrolytic solution holding layer 36 can further suppress leakage ofelectric currents when continuous float charging is carried out.

In this case, the porous polymer compound is formed, for example, in thefollowing manner. That is, firstly, a solution containing the inorganicparticles dispersed in a polar organic solvent is added to a solutioncontaining the same polymer material as in the above (vinylidenefluoride polymer) dissolved in a first solvent composed of a polarorganic solvent, such as N-methyl-2-pyrrolidone, γ-butyrolactone,N,N-dimethylacetamide, and N,N-dimethyl sulfoxide, so as to prepare acoating solution. The solution is coated on the separator 35. Next, theseparator 35 coated with the solution is immersed in a second solventwhich is compatible with the polar organic solvent, such as water, ethylalcohol, and propyl alcohol, and is a poor solvent with respect to thepolymer material. At this time, solvent exchange occurs, and phaseseparation accompanying spinodal decomposition occurs so that thepolymer material can form a porous structure. After that, a porouspolymer compound having a porous structure can be obtained by drying thepolymer material. Meanwhile, the electrolytic solution holding layer 36is formed by impregnating the electrolytic solution in the porouspolymer compound.

(Inorganic Particles)

The inorganic particles include particles of metallic oxides, particlesof metallic nitrides, particles of metallic carbides, and the like, allof which have electrical insulating properties. The metallic oxides thatcan be preferably used include alumina (Al₂O₃), magnesia (MgO), titania(TiO₂), zirconia (ZrO₂), silica (SiO₂), and the like. The metallicnitrides that can be preferably used include silicon nitride (Si₃N₄),aluminum nitride (AlN), boron nitride (BN), titanium nitride (TiN), andthe like. The metallic carbides that can be preferably used includesilicon carbide (SiC), boron carbide (B₄C), and the like. Theseinorganic particles may be used singly or in combination of two or morekinds The mass ratio of the vinylidene fluoride polymer to the inorganicparticles, or the vinylidene fluoride polymer: the inorganic particles,is, for example, 1:1 to 1:10. Since, when the added amount of theinorganic particles is too large, the adhesiveness between the positiveelectrode and the negative electrode becomes weak, the mass ratio of thevinylidene fluoride polymer to the inorganic particles is preferably 1:1to 1:8, and more preferably 1:2 to 1:6.

(Electrolytic Solution)

The electrolytic solution includes a solvent and an electrolyte saltthat is dissolved in the solvent.

(Solvent)

As the solvent, for example, a high-permittivity solvent can be used.The high-permittivity solvent that can be used includes cycliccarbonates, such as ethylene carbonate and propylene carbonate, and thelike. Instead of the cyclic carbonates or together with the cycliccarbonates, lactones, such as γ-butyrolactone and γ-valerolactone,lactams, such as N-methyl-pyrrolidone, cyclic carbamic acid esters, suchas N-methyloxazolidinone, or sulfone compounds, such as tetramethylenesulfone, may be used as the high-permittivity solvent.

A mixture of the high-permittivity solvent and a low-viscosity solventmay be used as the solvent. The low-viscosity solvent includeschain-like carbonate esters, such as ethyl methyl carbonate, diethylcarbonate, dimethyl carbonate, and methyl propyl carbonate; chain-likecarboxylate esters, such as methyl acetate, ethyl acetate, methylpropionate, ethyl propionate, methyl butyrate, methyl isobutyrate,methyl trimethylacetate, and ethyl trimethylacetate; chain-like amides,such as N,N-dimethylacetamide; chain-like carbamic acid esters, such asN,N-diethylcarbamyl methyl and N,N-diethylcarbamyl ethyl; ethers, suchas 1,2-dimethoxy ethane, tetrahydrofuran, tetrahydropyran, and1,3-dioxolane. Meanwhile, the solvent is not limited to the compounds asexemplified above, and compounds as suggested in the past can be widelyused.

(Electrolyte Salt)

The electrolyte salt contains, for example, one or two or more of lightmetal salts, such as lithium salts.

Examples of the lithium salts include inorganic lithium salts, such aslithium hexafluorophosphate (LiPF₆), lithium tetrafluoroborate (LiBF₄),lithium hexafluoroarsenate (LiAsF₆), lithium hexafluoroantimonate(LiSbF₆), lithium perchlorate (LiClO₄), and lithium tetrachloroaluminate(LiAlCl₄). In addition, examples of the lithium salts include lithiumsalts of perfluoroalkanesulfonate derivatives, such as lithiumtrifluoromethanesulfonate (CF₃SO₃Li), lithiumbis(trifluoromethanesulfonyl)imide ((CF₃SO₂)₂NLi), lithiumbis(pentafluoroethanesulfonyl)imide ((C₂F₅SO₂)₂NLi), and lithiumtris(trifluoromethanesulfonyl)methide ((CF₃SO₂)₃CLi); boron-containinglithium salts, such as lithium tetrafluoroborate (LiBF₄) and LiB(C₂O₄)₂;and the like.

(Method of Manufacturing the Non-Aqueous Electrolyte Battery)

The non-aqueous electrolyte battery is manufactured by, for example, thefollowing manufacturing method.

(Manufacturing of the Positive Electrode)

Firstly, the positive electrode 33 is manufactured. For example, apositive electrode material, a bonding agent, and a conducting agent aremixed so as to produce a positive electrode compound, and then thepositive electrode compound is dispersed in an organic solvent, therebyproducing a paste-like positive electrode compound slurry. Subsequently,the positive electrode compound slurry is evenly coated and dried onboth surfaces of the positive electrode collector 33A using a doctorblade or a bar coater. Lastly, the coated films are compacted using aroll press machine or the like while being heated according to necessityso as to form the positive electrode active material layer 33B. In thiscase, the compacting may be repeated plural times.

(Manufacturing of the Negative Electrode)

Next, the negative electrode 34 is manufactured. For example, a negativeelectrode material, a bonding agent, and, according to necessity, aconducting agent are mixed so as to produce a negative electrodecompound, and then the negative electrode compound is dispersed in anorganic solvent, thereby producing a paste-like negative electrodecompound slurry. Subsequently, the negative electrode compound slurry isevenly coated and dried on both surfaces of the negative electrodecollector 34A using a doctor blade or a bar coater. Lastly, the coatedfilms are compacted using a roll press machine or the like while beingheated according to necessity so as to form the negative electrodeactive material layer 34B.

(Formation of the Porous Polymer Compound)

Firstly, the above polymer material is coated on one surface or bothsurfaces of the separator 35. The polymer material is dissolved in thefirst solvent composed of a polar organic solvent, such asN-methyl-2-pyrrolidone, γ-butyrolactone, N,N-dimethylacetamide, andN,N-dimethyl sulfoxide, the solution is coated on the separator 35, theseparator 35 coated with the solution is immersed in the second solventwhich is compatible with the polar organic solvent, such as water, ethylalcohol, and propyl alcohol, and is a poor solvent with respect to thepolymer material, and dried. Thereby, the separator 35 having the porouspolymer compound formed on one surface or both surfaces is manufactured.

Next, the positive electrode lead 31 is attached to the positiveelectrode 33, and the negative electrode lead 32 is attached to thenegative electrode 34. Subsequently, the positive electrode 33 and thenegative electrode 34 are laminated through the separator 35 having theporous polymer compound formed on one surface or both surfaces, andwound. After that, the protective tape 37 is adhered on the outermostcircumferential portion so as to manufacture a wound body, which is aprecursor of the wound electrode body 30. The wound body is accommodatedin the bag-shaped exterior member 40.

After the electrolytic solution is prepared and injected into theexterior member 40, the opening portion of the exterior member 40 issealed through thermal fusion bonding and the like. Lastly, heatpressing is carried out. That is, the exterior member 40 is heated withapplication of a load, and the separator 35 is closely adhered to thepositive electrode 33 and the negative electrode 34 through the porouspolymer compound. Thereby, the electrolytic solution holding layer 36 isformed. During the hot press, the porous polymer compound swells in theelectrolytic solution holding layer 36, but the pore structure of theporous polymer compound is not collapsed, and the pores are maintained.Thereby, the non-aqueous electrolyte battery is completed.

2. Second Embodiment

(Configuration of the Non-Aqueous Electrolyte Battery)

An example of the configuration of the non-aqueous electrolyte batteryaccording to the second embodiment of the technology will be described.FIG. 3A is a perspective view showing the appearance of the non-aqueouselectrolyte battery according to the second embodiment of thetechnology. FIG. 3B is a perspective exploded view showing theconfiguration of the non-aqueous electrolyte battery according to thesecond embodiment of the technology. FIG. 3C is a perspective viewshowing the configuration of the bottom surface of the non-aqueouselectrolyte battery shown in FIG. 3A. Meanwhile, in the followingdescription, the portion in the non-aqueous electrolyte battery 51through which the positive electrode lead 53 is drawn out is consideredas the top portion, the portion which surfaces the top portion andthrough which the negative electrode lead 54 is drawn out is consideredas the bottom portion, and both sides interposed between the top portionand the bottom portion are considered as the side portions. In addition,description will be made with an assumption that the side portion toside portion direction of the electrodes and the electrode leads isconsidered as the width.

As shown in FIGS. 3A to 3C, the non-aqueous electrolyte battery 51 ofthe technology is, for example, a secondary battery that can be chargedand discharged, and has a battery element 60 covered with a laminatefilm 52. The positive electrode lead 53 and the negative electrode lead54, which are connected to the battery element 60, are drawn out towardthe outside of the battery from the portion at which the laminate film52 is sealed. The positive electrode lead 53 and the negative electrodelead 54 are drawn out from the mutually facing sides.

(Battery Element)

FIGS. 4A to 4B show examples of the configuration of the positiveelectrode composing the battery element. FIGS. 4C to 4B show examples ofthe configuration of the negative electrode composing the batteryelement. FIGS. 5A to 5B show an example of the configuration of thebattery element before being covered with a laminate film. The batteryelement 60 has a configuration in which a rectangular positive electrode61 shown in FIG. 4A or 4B and a rectangular negative electrode 62 shownin FIG. 4C and 4D are laminated through a separator 63. Specifically, inthe configuration, the positive electrode 61 and the negative electrode62 are mutually laminated through the separator 63 that is folded like ahairpin as shown in FIGS. 5A and 5B. In the second embodiment, thebattery element 60 in which the separator 63, the negative electrode 62,the separator 63, the positive electrode 61, . . . , the negativeelectrode 62, the separator 63 are laminated in this order so that theoutermost layer of the battery element 60 acts as the separator 63 isused. Meanwhile, although not shown in FIGS. 5A and 5B, a porous polymercompound is formed on both surfaces of the separator 63. An electrolyticsolution holding layer is formed by impregnating an electrolyticsolution in the porous polymer compound.

FIG. 6 is a cross-sectional view showing the VI-VI cross section of thenon-aqueous electrolyte battery in FIG. 3A. As shown in FIG. 6, in thebattery element 60, the electrolytic solution holding layers 66 areformed on both surfaces of the separator 63, and the separator 63 andthe positive electrode 61 and the separator 63 and the negativeelectrode 62 are adhered through the electrolytic solution holding layer66, respectively. In addition, the positive electrode 61 and thenegative electrode 62 are adhered through the insulating layer 67.Provision of the insulating layer 67 between the positive electrode 61and the negative electrode 62 increases the adhesiveness between thepositive electrode 61 and the negative electrode 62 so as to suppressthe inter-electrode distance from becoming uneven due to repetition ofcharging and discharging. Meanwhile, the electrolytic solution holdinglayer 66 may be formed on only one surface of the separator 63.

Positive electrode tabs 61C extended out respectively from plural sheetsof the positive electrode 61 and negative electrode tabs 62C extendedout respectively from plural sheets of the negative electrode 62 aredrawn out from the battery element 60. Positive electrode tabs 61Cstacked in plural sheets are configured to be folded so that the crosssection becomes an approximately U shape in a state of having anappropriate slack at the folded portion. The positive electrode lead 53is connected to the front end portion of the positive electrode tabs 61Cstacked in plural sheets by a method of ultrasonic welding, resistancewelding, or the like.

In addition, similarly to the positive electrode 61, the negativeelectrode tabs 62C are stacked in plural sheets, and configured to befolded so that the cross section becomes an approximately U shape in astate of having an appropriate slack at the folded portion. The negativeelectrode lead 54 is connected to the front end portion of the negativeelectrode tabs 62C stacked in plural sheets by a method of ultrasonicwelding, resistance welding, or the like.

(Positive Electrode Lead)

A metallic lead body composed of, for example, aluminum can be used asthe positive electrode lead 53 that is connected to the positiveelectrode tabs 61C. In the high-capacity non-aqueous electrolyte battery51 of the technology, the positive electrode lead 53 is set to be widerand thicker than in the past in order to draw large electric currentsout.

The width of the positive electrode lead 53 can be arbitrarily set, butthe width wa of the positive electrode lead 53 is preferably 50% or moreto 100% or less with respect to the width Wa of the positive electrode61 from the standpoint of drawing large electric currents out.

The thickness of the positive electrode lead 53 is preferably 150 μm ormore to 250 μm or less. When the thickness of the positive electrodelead 53 is less than 150 μm, the amount of electric current drawn outbecomes small. When the thickness of the positive electrode lead 53exceeds 250 μm, the positive electrode lead 53 is too thick, andtherefore the sealing performance of the laminate film 52 at the leaddrawing-out side is degraded, and moisture can easily intrude.

Meanwhile, a sealant 55, which is an adhering film for improving theadhesiveness between the laminate film 52 and the positive electrodelead 53, is provided at a part of the positive electrode lead 53. Thesealant 53 is composed of a resin material having a high adhesivenesswith a metallic material, and, for example, the sealant is preferablycomposed of a polyolefin resin, such as polyethylene, polypropylene,modified polyethylene, and modified polypropylene, when the positiveelectrode lead 53 is composed of the above metallic material.

The thickness of the sealant 55 is preferably 70 μm or more to 130 μm orless. When the thickness of the sealant is less than 70 μm, theadhesiveness between the positive electrode lead 53 and the laminatefilm 52 is degraded, and, when the thickness of the sealant exceeds 130μm, the flowing amount of a molten resin is large during thermal fusionbonding, which is not preferred for the manufacturing process.

(Negative Electrode Lead)

A metallic lead body composed of, for example, nickel (Ni) can be usedas the negative electrode lead 54 that is connected to the negativeelectrode tabs 62C. In the high-capacity non-aqueous electrolyte battery51 of the technology, the negative electrode lead 54 is set to be widerand thicker than in the past in order to draw large electric currentsout. It is preferable that the width of the negative electrode lead 54be substantially the same as the width of the negative electrode tabs62C as described below.

The width of the negative electrode lead 54 can be arbitrarily set, butthe width wb of the negative electrode lead 54 is preferably 50% or moreto 100% or less with respect to the width Wb of the negative electrode62 from the standpoint of drawing large electric currents out.

The thickness of the negative electrode lead 54 is, similarly to thethickness of the positive electrode lead 53, preferably 150 μm or moreto 250 μm or less. When the thickness of the negative electrode lead 54is less than 150 μm, the amount of electric current drawn out becomessmall. When the thickness of the negative electrode lead 54 exceeds 250μm, the negative electrode lead 54 is too thick, and therefore thesealing performance of the laminate film 52 at the lead drawing-out sideis degraded, and moisture can easily intrude.

Similarly to the positive electrode lead 53, the sealant 55, which is anadhering film for improving the adhesiveness between the laminate film52 and the negative electrode lead 54, is provided at a part of thenegative electrode lead 54.

Meanwhile, ordinarily, the width wa of the positive electrode lead 53and the width wb of the negative electrode lead 54 are the same width w(hereinafter, when the width wa of the positive electrode lead 53 andthe width wb of the negative electrode lead 54 are the same, the widthwa of the positive electrode lead 53 and the width wb of the negativeelectrode lead 54 are not differentiated, and are appropriately calledthe width w of the electrode lead). In addition, when the width Wa ofthe positive electrode 61 and the width Wb of the negative electrode 62are different, the width w of the electrode lead is preferably 50% ormore to 100% or less with respect to the width W of the electrode, whichis the wider of the width Wa of the positive electrode 61 and the widthWb of the negative electrode 62.

(Positive Electrode)

As shown in FIGS. 4A and 4B, the positive electrode 61 has the positiveelectrode active material layers 61B containing a positive electrodeactive material formed on both surfaces of the positive electrodecollector 61A. As the positive electrode collector 61A, for example, ametal foil, such as an aluminum (Al) foil, a nickel (Ni) foil, and astainless steel (SUS) foil, is used.

In addition, the positive electrode tab 61C is integrally extended outfrom the positive electrode collector 61A. The positive electrode tabs61C stacked in plural sheets are folded so that the cross sectionbecomes an approximately U-shape, and the positive electrode lead 53 isconnected to the front end portion by a method, such as ultravioletwelding or resistance welding.

The positive electrode active material layer 61B is formed on therectangular main surface portion of the positive electrode collector61A. The extended-out portion in a state in which the positive electrodecollector 61 is exposed is provided with functions as the positiveelectrode tab 61C, which is a connecting tab for connecting the positiveelectrode lead 53. The width of the positive electrode tab 61C can bearbitrarily set. Particularly, when the positive electrode lead 53 andthe negative electrode lead 54 are drawn out from the same side, thewidth of the positive electrode tab 61C should be less than 50% of thewidth of the positive electrode 61. The positive electrode 61 isobtained by forming the positive electrode active material layer 61B atone side of the rectangular positive electrode collector 61A so as toprovide the positive electrode collector exposed portion and cuttingunnecessary portions.

The configuration of the positive electrode active material layer 61B isthe same as that of the positive electrode active material layer 33B ofthe first embodiment. That is, the positive electrode active materiallayer 61B includes one or two or more of positive electrode materialsthat can absorb and discharge lithium as the positive electrode activematerial, and may also include other materials, such as a bonding agentand a conducting agent, according to necessity. The positive electrodematerial, the bonding agent, and the conducting agent are the same as inthe first embodiment.

(Negative Electrode)

As shown in FIGS. 4C and 4D, the negative electrode 62 has the negativeelectrode active material layers 62B containing a negative electrodeactive material formed on both surfaces of the negative electrodecollector 62A. The negative electrode collector 62A is composed of, forexample, a metal foil, such as a copper (Cu) foil, a nickel (Ni) foil,and a stainless steel (SUS) foil.

In addition, the negative electrode tab 62C is integrally extended outfrom the negative electrode collector 62A. The negative electrode tabs62C stacked in plural sheets are folded so that the cross sectionbecomes an approximately U-shape, and the negative electrode lead 54 isconnected to the front end portion by a method, such as ultravioletwelding or resistance welding.

The negative electrode active material layer 62B is formed on therectangular main surface portion of the negative electrode collector62A. The extended-out portion in a state in which the negative electrodecollector 62A is exposed is provided with functions as the negativeelectrode tab 62C, which is a connecting tab for connecting the negativeelectrode lead 54. The width of the negative electrode tab 62C can bearbitrarily set. Particularly, when the positive electrode lead 53 andthe negative electrode lead 54 are drawn out from the same side, thewidth of the negative electrode tab 62C should be less than 50% of thewidth of the negative electrode 62. The negative electrode 62 isobtained by forming the negative electrode active material layer 62B atone side of the rectangular negative electrode collector 62A so as toprovide the negative electrode collector exposed portion and cuttingunnecessary portions.

(Negative Electrode Active Material Layer)

The configuration of the negative electrode active material layer 62B isthe same as that of the negative electrode active material layer 62B ofthe first embodiment. That is, the negative electrode active materiallayer 62B includes one or two or more of negative electrode materialsthat can absorb and discharge lithium as the negative electrode activematerial, and may also include other materials, such as a bonding agentand a conducting agent, according to necessity. The negative electrodematerial, the bonding agent, and the conducting agent are the same as inthe first embodiment.

(Insulating Layer)

An insulating layer 67 is composed of a separator 63 and an electrolyticsolution holding layer 66 formed on at least one surface of theseparator 63. Meanwhile, the insulating layer 67 may be composed of onlythe electrolytic solution holding layer 66 without the separator 63.

(Separator)

The separator 63 is composed of an insulating thin film having a largeion permeability and a predetermined mechanical strength. Specifically,the separator 63 is composed of a porous film composed of apolyolefin-based material, such as polypropylene (PP) and polyethylene(PE), or a porous film composed of an inorganic material, such as aceramic non-woven fabric, and may have a structure in which porous filmsof two or more of the above are laminated. Among them, a separatorincluding a polyolefin-based porous film, such as polyethylene andpolypropylene, is preferred since the separator is excellent in terms ofthe properties of separating the positive electrode 61 and the negativeelectrode 62, and internal short-circuiting or degradation of opencircuit voltage can be further reduced. The electrolytic solution isimpregnated in the separator 63.

(Electrolytic Solution Holding Layer)

The electrolytic solution holding layer 66 is the same as theelectrolytic solution holding layer 36 of the first embodiment. That is,the electrolytic solution holding layer 66 includes the same porouspolymer compound as in the first embodiment and the same electrolyticsolution as in the first embodiment. In the electrolytic solutionholding layer 66, the electrolytic solution is held in the pores in theporous polymer compound and swells the porous polymer compound.Meanwhile, the electrolytic solution holding layer 66 may have functionsof, singly or together with the separator 63, separating the positiveelectrode 61 and the negative electrode 63, preventing short-circuitingof electric currents caused by contact of both electrodes, and passinglithium ions.

In the high-capacity non-aqueous electrolyte battery of the technology,the thickness of the separator that can be used is preferably 5 μm ormore to 25 μm or less, and more preferably 7 μm or more to 20 μm orless. When the separator 63 is too thick, the packing amount of theactive material is lowered so as to degrade the battery capacity, andthe ion conductivity is degraded so as to degrade the electric currentcharacteristics. Inversely, when the separator 63 is too thin, themechanical strength of the film is degraded.

Similarly to the first embodiment, the electrolytic solution holdinglayer 66 also may contain inorganic particles in addition to the porouspolymer compound and the electrolytic solution. The inorganic particlesbeing contained in the electrolytic solution holding layer 66 canfurther suppress leakage of electric currents when continuous floatcharging is carried out.

The thickness of the battery element 60 is preferably 5 mm or more to 20mm or less. When the thickness is less than 5 mm, since the batteryelement is thin, the battery element tends to be less affected by heatstorage and easily lose heat even when there re no recesses andprotrusions on the battery surface. On the other hand, when thethickness exceeds 20 mm, the distance from the battery surface to thebattery central portion becomes too large such that there is a tendencyfor a temperature difference to occur in the battery due to only heatradiation from the battery surface, and the service life performance isaffected.

In addition, the discharge capacity of the battery element 60 ispreferably 3 Ah or more to 50 Ah or less. When the discharge capacity isless than 3 Ah, since the discharge capacity is small, there is atendency that heat generation can be suppressed even by other methods,such as increasing the thickness of the collecting foil or the like soas to lower the battery capacity and thus decrease the resistance. Whenthe discharge capacity exceeds 50 Ah, there is a tendency that the heatcapacity of the battery is increased, and it becomes difficult toradiate heat such that temperature variation in the battery isincreased. Here, the discharge capacity of the battery element 60 is thenominal capacity of the non-aqueous electrolyte battery 1, and thenominal capacity is computed from the discharge capacities in the casesof constant voltage and constant current charging under the chargingconditions of the upper limit voltage of 3.6 V and the charging currentof 0.2 C and constant current discharging under the dischargingconditions of the discharge final voltage of 2.0 V and the dischargingcurrent of 0.2 C.

(Laminate Film)

The laminate film 52, which is an exterior body that covers the batteryelement 60, has a configuration in which resin layers are provided onboth surfaces of a metal layer 52 a composed of a metal foil. Anordinary configuration of the laminate film can be expressed by alaminate structure of an outside resin layer 52 b/a metal layer 52 a/aninside resin layer 52 c as shown in FIG. 7, and the inside resin layer52 c surfaces the battery element 60. Adhering layers having a thicknessof about 2 μm or more to 7 μm or less may also be provided among theoutside resin layer 52 b, the inside resin layer 52 c, and the metallayer 52 a. Each of the outside resin layer 52 b and the inside resinlayer 52 c may also be composed of plural layers.

Any metallic materials can be used to compose the metal layer 52 a aslong as the metallic materials are provided with functions as amoisture-resistant barrier film, and the metallic materials that can beused include an aluminum (Al) foil, a stainless steel (SUS) foil, anickel (Ni) foil, a coated iron (Fe) foil, and the like. Among them, itis preferable to use an aluminum foil that is thin, light, and excellentin terms of workability. Particularly, it is preferable to use, forexample, annealed aluminum (JIS A8021P-O), (JIS A8079P-O), (JISAlN30-0), and the like from the standpoint of workability.

The thickness of the metal layer 52 a is preferably 30 μm or more to 150μm or less. When the thickness of the metal layer 52 a is less than 30μm, the strength of the material is degraded. In addition, when thethickness of the metal layer 52 a exceeds 150 μm, working becomessignificantly difficult, and the thickness of the laminate film 52 isincreased, which leads to degradation of the volume efficiency of thenon-aqueous electrolyte battery.

The inside resin layer 52 c is a portion that is melted by heat and isthermally fused mutually, and polyethylene (PE), cast propylene (CPP),polyethylene terephthalate (PET), low-density polyethylene (LDPE),high-density polyethylene (HDPE), linear low-density polyethylene(LLDPE), and the like can be used for the inside resin layer. It is alsopossible to select and use plural kinds from the above.

The thickness of the inside resin layer 52 c is preferably set to 20 μmor more to 50 μm or less. When the thickness of the inside resin layeris less than 20 μm, the adhesiveness is degraded, the pressure bufferingaction becomes insufficient, and short-circuiting becomes liable tooccur. In addition, when the thickness of the inside resin layer exceeds50 μm, it becomes easy for moisture to intrude through the inside resinlayer 52 c, and there is a concern that gas generation and the resultingbattery swelling and degradation of battery characteristics may occur inthe battery. Meanwhile, the thickness of the inside resin layer 52 c isthe thickness in a state in which the battery element 60 is not yetcovered. When the battery element 60 is covered with the laminate film52 and sealed, since two layers of the inside resin layer 52 c arethermally fused mutually, there are cases in which the thickness of theinside resin layer 52 c is outside the above range.

Meanwhile, the inside resin layer 52 c may have recesses and protrusionsprovided on the surface by, for example, embossing or the like. Thereby,the slip properties of the outermost layer of the battery element 60between the electrolytic solution holding layer 66 and the laminate film52 are deteriorated, and the effect of suppressing the movement of thebattery element 60 can be increased.

In terms of an aesthetically-pleasing appearance, toughness,flexibility, and the like, a polyolefin-based resin, a polyamide-basedresin, a polyimide-based resin, polyester, or the like can be used asthe outside resin layer 52 b. Specifically, nylon (Ny), polyethyleneterephthalate (PET), polyethylene naphthalate (PEN), polybutyleneterephthalate (PBT), or polybutylene naphthalate (PBN) can be used, andit is also possible to select and use plural kinds from the above.

Meanwhile, since the inside resin layer 52 c is fused by thermal fusionbonding so as to bond the laminate films 52, the outside resin layer 52b preferably has a higher melting point than the inside resin layer 52c. This is for fusing only the inside resin layer 52 c during thermalfusion bonding. Therefore, for the outside resin layer 52 b, a usablematerial can be selected according to a resin material selected for theinside resin layer 52 c.

The thickness of the outside resin layer 52 b is preferably set to 25 μmor more to 35 μm or less. When the thickness of the outside resin layeris less than 25 μm, the functions as a protective layer are degraded,and, when the thickness of the outside resin layer exceeds 35 μm, thevolume efficiency of the non-aqueous electrolyte battery 51 is degraded.

The battery element 60 is covered with the laminate films 52. At thistime, the positive electrode lead 53 connected to the positive electrodetab 61C and the negative electrode lead 54 connected to the negativeelectrode tab 62C are drawn out to the outside of the battery from thesealed portion of the laminate films 52. As shown in FIG. 3B, a batteryelement accommodating portion 57 formed by a deep drawing process inadvance is provided between the laminate films 52. The battery element60 is accommodated in the battery element accommodating portion 57.

In the technology, the peripheral portion of the battery element 60 isheated using a heater head so as to thermally fuse and seal the laminatefilms 52 which cover the battery element 60 from both surfaces.Particularly, it is preferable to thermally fuse the laminate films 52using the heater head provided with a notch in a shape that can avoidthe positive electrode lead 53 and the negative electrode lead 54 in thelead drawing-out sides. This is because the battery can be manufacturedwith a reduced load which is applied to the positive electrode lead 53and the negative electrode lead 54. This method can prevent shortingduring the manufacturing of the battery.

The non-aqueous electrolyte battery 51 of the technology obtains goodstability and battery characteristics by controlling the thickness ofthe lead drawing-out portion after the laminate films 52 are sealedthrough thermal fusion bonding.

(Method of Manufacturing the Non-Aqueous Electrolyte Battery)

The above non-aqueous electrolyte battery 51 can be manufactured by, forexample, the following process.

(Manufacturing of the Positive Electrode)

A positive electrode material, a conducting agent, and a bonding agentare mixed so as to prepare a positive electrode compound, and thepositive electrode compound is dispersed in a solvent, such asN-methyl-2-pyrrolidone, so as to produce a positive electrode compoundslurry. Subsequently, the positive electrode compound slurry is coatedon both surfaces of the band-shaped positive electrode collector 61A,and the solvent is dried. Then, compacting is carried out using a rollpress machine or the like so as to form the positive electrode activematerial layer 61B, thereby producing a positive electrode sheet. Thepositive electrode sheet is cut to have predetermined dimensions, andthe positive electrode 61 is manufactured. At this time, the positiveelectrode active material layer 61B is formed so that a part of thepositive electrode collector 61A is exposed. The positive electrodecollector 61A exposed portion is used as the positive electrode tab 61C.In addition, the positive electrode tab 61C may be formed by cuttingunnecessary portions in the positive electrode collector exposed portionaccording to necessity. Thereby, the positive electrode 61 having thepositive electrode tab 61C integrally formed is obtained.

(Manufacturing of the Negative Electrode)

A negative electrode material and a bonding agent are mixed so as toprepare a negative electrode compound, and the negative electrodecompound is dispersed in a solvent, such as N-methyl-2-pyrrolidone, soas to produce a negative electrode compound slurry. Subsequently, thenegative electrode compound slurry is coated on the negative electrodecollector 62A, and the solvent is dried. Then, compacting was carriedout using a roll press machine or the like so as to form the negativeelectrode active material layer 62B, thereby producing a negativeelectrode sheet. The negative electrode sheet is cut to havepredetermined dimensions, and the negative electrode 62 is manufactured.At this time, the negative electrode active material layer 62B is formedso that a part of the negative electrode collector 62A is exposed. Thenegative electrode collector 62A exposed portion is used as the negativeelectrode tab 62C. In addition, the negative electrode tab 62C may beformed by cutting unnecessary portions in the negative electrodecollector exposed portion according to necessity. Thereby, the negativeelectrode 62 having the negative electrode tab 62C integrally formed isobtained.

(Formation of the Porous Polymer Compound)

A porous polymer compound is formed on the surface of the separator 63.The porous polymer compound is formed, for example, in the followingmanner. That is, firstly, a solution containing a polymer materialdissolved in a first solvent composed of a polar organic solvent, suchas N-methyl-2-pyrrolidone, γ-butyrolactone, N,N-dimethylacetamide, andN,N-dimethyl sulfoxide, is prepared, and the solution is coated on theseparator 63. Next, the separator 63 coated with the solution isimmersed in a second solvent which is compatible with the polar organicsolvent, such as water, ethyl alcohol, and propyl alcohol, and is a poorsolvent with respect to the polymer material. At this time, solventexchange occurs, and phase separation accompanying spinodaldecomposition occurs so that the polymer material can form a porousstructure. Meanwhile, the electrolytic solution holding layer 66 isformed by impregnating the electrolytic solution in the porous polymercompound.

(Laminating Process)

Next, as shown in FIGS. 5A and 5B, the positive electrode 61 and thenegative electrode 62 are alternately inserted in the hairpin-likefolded separator 63, and the predetermined number of the positiveelectrodes 61 and the negative electrodes 62 are laminated so that, forexample, the separator 63, the negative electrode 62, the separator 63,the positive electrode 61, the separator 63, the negative electrode 62,. . . , the separator 63, the negative electrode 62, the separator 63are stacked. Subsequently, the positive electrode 61, the negativeelectrode 62, and the separator 63 are fixed in a pressed state so as tobe closely adhered, thereby manufacturing the battery element 60. It ispossible to use a fixing member 56, for example, an adhering tape or thelike, in order to further strongly fix the battery element 60. When thebattery element is fixed using the fixing member 56, the fixing member56 is provided at, for example, both side portions of the batteryelement 60.

Next, plural sheets of the positive electrode tab 61C and plural sheetsof the negative electrode tab 62C are folded so as to form a U-shapedcross section. The electrode tabs are folded, for example, in thefollowing manner.

(First Process of Folding the Tab into a U Shape)

A plurality of positive electrode tabs 61C pulled out from the laminatedpositive electrodes 61 and a plurality of negative electrode tabs 62Cpulled out from the laminated negative electrodes 62 are folded so thatthe cross section becomes an approximately U shape. The first process offolding into a U shape is a process for providing an optimal U-likefolded shape to the positive electrode tabs 61C and the negativeelectrode tabs 62C in advance. Provision of the optimal U-like foldedshape in advance can prevent stress, such as tensile stress, from beingapplied to the positive electrode tabs 61C and the negative electrodetabs 62C when the positive electrode lead 53, the negative electrodelead 54, the connected positive electrode tabs 61C and negativeelectrode tabs 62C are folded so as to form U-like folded portions.

FIGS. 8A to 8E are side surface views that explain the first process offolding the negative electrode tabs 62C into a U shape. In FIGS. 8A to8E, the respective processes carried out on the negative electrode tabs62C are explained. Meanwhile, the first process of folding into a Ushape is also carried out on the positive electrode collector 61A in thesame manner.

Firstly, as shown in FIG. 8A, the battery element is disposed on the topportion of a work set table 70 a having a thin plate for folding into aU shape 71. The thin plate for folding into a U shape 71 is provided soas to protrude from the work set table 70 a slightly less, specifically,at least the total thickness of a plurality of the negative electrodetab 62C₁ to the negative electrode tab 62C₄ less than the thickness ofthe battery element 60. In this configuration, since the folded outercircumferential side of the negative electrode tab 62C₄ is locatedwithin the range of the thickness of the battery element 60, an increasein the thickness of the non-aqueous electrolyte battery 51 or occurrenceof poor appearance can be prevented.

Subsequently, as shown in FIG. 8B, the battery element 60 is moved down,or the work set table 70 a is moved up. At this time, since the spaceefficiency of the non-aqueous electrolyte battery 51 is improved as thegap between the battery element 60 and the thin plate for folding into aU shape 71 is decreased, for example, the gap between the batteryelement 60 and the thin plate for folding into a U shape 71 is made todecrease gradually.

After the battery element 60 is mounted on the work set table 70 a, anda folded portion is formed in the negative electrode tab 62C as shown inFIG. 8C, a roller 72 is moved down so that the negative electrode tab62C is folded into a U shape as shown in FIGS. 8D and 8E.

The thickness of the thin plate for folding into a U shape 71 is 1 mm orless, and preferably, for example, about 0.5 mm. For the thin plate forfolding into a U shape 71, it is possible to use a material having anecessary strength to form a folded shape in a plurality of the positiveelectrode tabs 61C or the negative electrode tabs 62C even with such athin thickness. The necessary strength of the thin plate for foldinginto a U shape 71 varies with the number of the laminated sheets of thepositive electrode 61 or the negative electrode 62, the hardness of amaterial used for the positive electrode tab 61C and the negativeelectrode tab 62C, and the like. As the thin plate for folding into a Ushape 71 is thinner, the curvature of the negative electrode tab 62C₁ atthe innermost folded circumference can be reduced, and therefore thenecessary space to fold the negative electrode tab 62C can be reduced,which is preferable. Examples of the thin plate for folding into a Ushape 71 that can be used include stainless steel (SUS), a reinforcedplastic material, a coated steel material, and the like.

(Process of Cutting the Collector Exposed Portion)

Next, the front end of the negative electrode tab 62C having the U-likefolded portion formed is cut to have the same dimensions. In the processof cutting the collector exposed portion, a U-like folded portion havingan optimal shape in advance is formed, and the excess portions of thepositive electrode tab 61C and the negative electrode tab 62C are cutaccording to the U-like folded shape. FIGS. 9A to 9E are side surfaceviews that explain the process of cutting the negative electrode tab62C. Meanwhile, the process of cutting the collector exposed portion isalso carried out on the positive electrode tab 61C in the same manner.

As shown in FIG. 9A, the top surface and the bottom surface of thebattery element 60, in which a U-like folded portion is formed in thefirst process of folding into a U shape, are turned over, and thebattery element 60 is fixed on a work set table 70 b having an escapingportion for collector slack 73.

Next, as shown in FIG. 9B, the front end portion which occupies from theU-like folded portions of the negative electrode tab 62C₁ to thenegative electrode tab 62C₄ having the U-like folded portions formed tothe front end is deformed so that the front end portion forms anapproximately L shape along the work set table 70 b. At this time,maintaining a necessary shape to form a U-like folded portion againgenerates a slack as large as the negative electrode tab 62C₄ on thefolded outer circumference side. Such a slack enters the escapingportion for collector slack 73 in the work set table 70 b so that thenegative electrode tab 62C₁ to the negative electrode tab 62C₄ can bedeformed without stress. Meanwhile, the negative electrode tab 62C₁ tothe negative electrode tab 62C₄ may be deformed in a state in which thefront end portion of the negative electrode tab 62C₁ to the negativeelectrode tab 62C₄ is fixed.

Subsequently, after the negative electrode tab 62C₁ to the negativeelectrode tab 62C₄ are held on the work set table 70 b using a collectorholding member 74 as shown in FIG. 9C, for example, the front ends ofthe negative electrode tab 62C₁ to the negative electrode tab 62C₄ arecut to have the same dimensions using, for example, a cutting blade 75provided so as to go along with the collector holding member 74 as shownin FIGS. 9D and 9E. In the cut portions of the negative electrode tab62C₁ to the negative electrode tab 62C₄, at least the excess portions inthe front ends of the negative electrode tab 62C₁ to the negativeelectrode tab 62C₄ are cut so that the front ends of the negativeelectrode tab 62C₁ to the negative electrode tab 62C₄ are located withinthe range of the thickness of the battery element 60 when U-like foldingis carried out again later.

(Process of Connecting the Electrode Lead)

Subsequently, connection between the negative electrode tab 62C₁ to thenegative electrode tab 62C₄ and the negative electrode lead 54 iscarried out. In a process of connecting the tab, the positive electrodetab 61C and the negative electrode tab 62C, and the positive electrodelead 53 and the negative electrode lead 54 are fixed while the optimalU-like folded shape formed in the first process of folding into a Ushape is maintained. Thereby, the positive electrode tab 61C and thepositive electrode lead 53, and the negative electrode tab 62C and thenegative electrode tab 54 are electrically connected. FIGS. 10A to 10Care side surface views that explain the process of connecting thenegative electrode tab 62C₁ to the negative electrode tab 62C₄ and thenegative electrode lead 54. Meanwhile, although not shown, the sealant55 is provided in advance in the negative electrode lead 54. Theconnecting process is also carried out on the positive electrode tab 61Cand the positive electrode lead 53 in the same manner.

As shown in FIG. 10A, the top surface and the bottom surface of thebattery element 60, for which the excess portions at the front ends ofthe negative electrode tab 62C₁ to the negative electrode tab 62C₄ arecut is again turned over. Next, as shown in FIG. 10B, the batteryelement 60 is fixed on a work set table 70 c having a plate for formingand maintaining the collector 76. The front end of the plate for formingand maintaining the collector 76 is located on the folded innercircumference side of the negative electrode tag 62C₁ so as to maintainthe folded shapes of the negative electrode tab 62C₁ to the negativeelectrode tab 62C₄ and prevent the influences of external causes, suchas ultrasonic vibration generated from an anchoring device.

Subsequently, as shown in Table 10C, the negative electrode tab 62C₁ tothe negative electrode tab 62C₄ and the negative electrode lead 54 arefixed by, for example, ultrasonic welding. For example, an anvil 77 aprovided beneath the bottom portion of the negative electrode tab 62C₁to the negative electrode tab 62C₄ and a horn 77 b provided on the topportion of the negative electrode tab 62C₁ to the negative electrode tab62C₄ are used for ultrasonic welding. The negative electrode tab 62C₁ tothe negative electrode tab 62C₄ are set in the anvil 77 a in advance,and the horn 77 b is moved down so as to interpose the negativeelectrode tab 62C₁ to the negative electrode tab 62C₄ and the negativeelectrode lead 54 with the anvil 77 a and the horn 77 b. In addition,the anvil 77 a and the horn 77 b supply ultrasonic vibrations to thenegative electrode tab 62C₁ to the negative electrode tab 62C₄ and thenegative electrode lead 54. Thereby, the negative electrode tab 62C₁ tothe negative electrode tab 62C₄ and the negative electrode lead 54 aremutually anchored.

Meanwhile, in the process of connecting the tab, the negative electrodelead 54 may be connected to the negative electrode tab 62C so as to formthe above inner circumferential folding Ri with reference to FIG. 10C.Meanwhile, the inner circumferential folding Ri is set to the thicknessor more of the positive electrode lead 53 and the negative electrodelead 54.

Next, the negative electrode lead 54 having the negative electrode tab62C₁ to the negative electrode tab 62C₄ fixed is folded into apredetermined shape. FIGS. 11A to 11E are side surface views thatexplain a process of folding the tab of the negative electrode lead 54.In addition, the process of folding the tab and the process ofconnecting the electrode lead are also carried out on the positiveelectrode tab 61C and the positive electrode lead 53 in the same manner.

As shown in FIG. 11A, the top surface and the bottom surface of thebattery element 60 having the negative electrode tab 62C₁ to thenegative electrode tab 62C₄ and the negative electrode lead 54 fixed inthe connecting process are again turned over, and the battery element 60is fixed on a work set table 70 d having the escaping portion forcollector slack 73. The connection portion between the negativeelectrode tab 62C₁ to the negative electrode tab 62C₄ and the negativeelectrode lead 54 is mounted on a tab folding table 78 a.

Subsequently, the connection portion between the negative electrode tab62C₁ to the negative electrode tab 62C₄ and the negative electrode lead54 is held by a block 78 b as shown in FIG. 11B, and the negativeelectrode lead 54 protruding from the tab folding table 78 a and theblock 78 b is folded by moving down a roller 79 as shown in FIG. 11C.

(A Second Process of Folding the Tab into a U Shape)

Subsequently, as shown in FIG. 11D, the thin plate for folding into a Ushape 71 is disposed between the battery element 60 and the block 78 bthat holds the negative electrode tab 62C₁ to the negative electrode tab62C₄. Subsequently, as shown in FIG. 11E, the negative electrode tab62C₁ to the negative electrode tab 62C₄ are 90° folded along the U-likefolded shape formed in the first process of folding into a U shape whichis shown in FIGS. 8A to 8E, thereby manufacturing the battery element60. At this time, as described above, the negative electrode lead 54 andthe negative electrode tab 62C are connected so as to form the innercircumferential folding Ri as shown in FIG. 10C. Thereby, it is possibleto fold the negative electrode tab 62C in the substantiallyperpendicular direction to the electrode surface without the contactbetween the negative electrode lead 54 and the laminated positiveelectrode 61 and negative electrode 62 in the second process of foldingthe tab into a U shape.

At this time, it is preferable to fold the negative electrode lead 54together with the sealant 55 which is thermally fused in advance. Thefolded portion in the negative electrode lead 54 is covered with thesealant 55 so that a structure in which the negative electrode lead 54and the laminate film 52 are not in direct contact with each other canbe made. This structure can significantly reduce the friction betweenthe resin layers and the negative electrode lead 54 in the laminate film52, damage of the laminate film 52, and a risk of short-circuiting ofthe laminate film 52 with the metal layer, all of which are caused bylong-term vibrations, impact, and the like. The battery element 60 ismanufactured in the above manner.

(Covering Process)

After that, the manufactured battery element 60 is covered with thelaminate film 52, and one of the side portions, the top portion, and thebottom portion are heated using the heater head and thermally fused. Thetop portion and the bottom portion, through which the positive electrodelead 53 and the negative electrode lead 54 are drawn out, are heatedusing, for example, a heater head having a notch, and thermally fused.

Subsequently, an electrolytic solution is injected through an opening inthe other side portion that is not thermally fused. Finally, thelaminate film 52 in the side portion through which the electrolyticsolution is injected is thermally fused, and the battery element 60 issealed in the laminate film 52. After that, heat pressing in which thebattery element 60 is pressurized and heated from the outside of thelaminate film 52 is carried out, and the electrolytic solution is heldin the porous polymer compound formed on the surface of the separator63. Thereby, the electrolytic solution holding layer 66 is formed.During the hot press, the porous polymer compound swells in theelectrolytic solution holding layer 66, but the pore structure of theporous polymer compound is not collapsed, and the pores are maintained.Thereby, the non-aqueous electrolyte battery 51 is completed.

3. Third Embodiment

(Configuration of the Non-Aqueous Electrolyte Battery)

The non-aqueous electrolyte battery according to the third embodiment ofthe technology will be described. FIG. 12A is a perspective view showingthe appearance of the non-aqueous electrolyte battery according to thethird embodiment of the technology, and FIG. 12B is an explodedperspective view showing the configuration of the non-aqueouselectrolyte battery according to the third embodiment of the technology.In addition, FIG. 12C is a perspective view showing the configuration ofthe bottom surface of the non-aqueous electrolyte battery shown in FIG.12A.

The non-aqueous electrolyte battery of the third embodiment is the sameas in the second embodiment except that the configuration and the likeof the battery element are different from those of the secondembodiment. Therefore, in the following, the differences from the secondembodiment will be mainly described, and the overlapped portions withthe second embodiment will not be described. Meanwhile, in FIGS. 12A to14B, the similar or corresponding portions to those of the non-aqueouselectrolyte battery of the second embodiment will be given similarreference symbols. In addition, in the following description, theportion in the non-aqueous electrolyte battery 81 through which thepositive electrode lead 53 and the negative electrode lead 54 are drawnout is considered as the top portion, the portion facing the top portionis considered as the bottom portion, and both sides interposed betweenthe top portion and the bottom portion are considered as the sideportions. In addition, description will be made with an assumption thatthe side portion to side portion direction of the electrodes and theelectrode leads is considered as the width.

As shown in FIGS. 12A to 12C, the non-aqueous electrolyte battery 81 ofthe third embodiment is, for example, a secondary battery that can becharged and discharged, and has a battery element 90 covered with thelaminate film 52. In the non-aqueous electrolyte battery 81, thepositive electrode lead 53 and the negative electrode lead 54, which areconnected to the battery element 90, are drawn out to the outside of thebattery from the portion at which the laminate films 52 are sealed. Thepositive electrode lead 53 and the negative electrode lead 54 are drawnout from the same side.

The width wa of the positive electrode lead 53 should be less than 50%of the width Wa of the positive electrode 61. This is because thepositive electrode lead 53 should be provided at a location at which thepositive electrode lead 53 does not come into contact with the negativeelectrode lead 54. In addition, in this case, the width wa of thepositive electrode lead 53 is preferably 15% or more to 40% or less, andmore preferably 35% or more to 40% or less of the width Wa of thepositive electrode 61 in order to satisfy both the sealing properties ofthe laminate film 52 and high electric current charging and discharging.In addition, the width wb of the negative electrode lead 54 should beless than 50% of the width Wb of the negative electrode 62. This isbecause the negative electrode lead 54 should be provided at a locationat which the negative electrode lead 54 does not come into contact withthe positive electrode lead 53. In addition, in this case, the width wbof the negative electrode lead 54 is preferably 15% or more to 40% orless, and more preferably 35% or more to 40% or less of the width Wa ofthe negative electrode 62 in order to satisfy both the sealingproperties of the laminate film 52 and high electric current chargingand discharging.

(Battery Element)

FIGS. 13A to 13B show an example of the configuration of the batteryelement that is not yet covered with the laminate film. The batteryelement 60 has a configuration in which the substantially rectangularpositive electrode 61 and the substantially rectangular negativeelectrode 62 disposed opposite to the positive electrode 61 arelaminated sequentially through the substantially rectangular separator63. Specifically, the battery element 60 has a laminate-type electrodestructure in which the negative electrode 62, the separator 63, thepositive electrode 61, the separator 63, . . . , the separator 63, thenegative electrode 62 are alternately laminated. The positive electrode61 and the negative electrode 62 in the third embodiment have the sameconfigurations as in the second embodiment. Meanwhile, although notshown, the porous polymer compound is formed on both surfaces of theseparator 63. The electrolytic solution holding layer 66 is formed byimpregnating an electrolytic solution in the porous polymer compound.

FIG. 14A is a cross-sectional view showing the cross section of thenon-aqueous electrolyte battery taken along the XIVA-XIVA in FIG. 12A.FIG. 14B is a cross-sectional view showing the cross section of thenon-aqueous electrolyte battery taken along the XIVB-XIVB in FIG. 12A.As shown in FIGS. 14A to 14B, in the battery element 60, theelectrolytic solution holding layer 66 is formed on both surfaces of theseparator 63, and the separator 63 and the positive electrode 61, andthe separator 63 and the negative electrode 62 are adhered through theinsulating layer 66, respectively. In addition, the positive electrode61 and the negative electrode 62 are adhered through the insulatinglayer 67. Provision of the insulating layer 67 between the positiveelectrode 61 and the negative electrode 62 increases the adhesivenessbetween the positive electrode 61 and the negative electrode 62 so as tosuppress the inter-electrode distance from becoming uneven due torepetition of charging and discharging. Meanwhile, the electrolyticsolution holding layer 66 may be formed on only one surface of theseparator 63.

The positive electrode tab 61C as the positive electrode terminal thatis electrically connected to plural sheets of the positive electrode 61respectively and the negative electrode tab 62C as the negativeelectrode terminal that is electrically connected to plural sheets ofthe negative electrode 62 respectively are pulled out from the batteryelement 90. The positive electrode lead 53 and the negative electrodelead 54 are connected to plural sheets of the positive electrode tabs61C and negative electrode tabs 62C, respectively, by resistancewelding, ultrasonic welding, or the like. Furthermore, the positiveelectrode tabs 61C and the negative electrode tabs 62C, which arestacked in plural sheets, are configured so that the cross sectionbecomes an approximately U shape. The positive electrode tabs 61C andthe negative electrode tabs 62C are folded into a U shape in a state ofhaving an appropriate slack at the folded portion.

(Method of Manufacturing the Non-Aqueous Electrolyte Battery)

The non-aqueous electrolyte battery 81 can be manufactured by, forexample, the following process.

(Formation of the Positive Electrode, the Negative Electrode, and thePorous Polymer Compound)

The positive electrode 61 and the negative electrode 62 can bemanufactured by the same method as in the second embodiment. Inaddition, the porous polymer compound is formed on the surface of theseparator 63 by the same method as in the second embodiment.

(Laminating Process)

Next, as shown in FIGS. 13A and 13B, the predetermined number of thepositive electrodes 61 and the negative electrodes 62 are laminatedthrough the rectangular separator 63 so that, for example, the negativeelectrode 62, the separator 63, the positive electrode 61, the separator63, . . . , the separator 63, and the negative electrode 62 are stacked.Subsequently, the positive electrode 61, the negative electrode 62, andthe separator 63 are fixed in a pressed state so as to be closelyadhered, thereby manufacturing the battery element 90.

The battery element 90 manufactured in the above manner has the positiveelectrode tabs 61C and the negative electrode tabs 62C folded like a Ushaped by the same method as in the second embodiment.

(Covering Process)

After that, the manufactured battery element 90 is covered with thelaminate film 52, and one of the side portions, the top portion, and thebottom portion are heated using the heater head and thermally fused. Thetop portion and the bottom portion, through which the positive electrodelead 53 and the negative electrode lead 54 are drawn out, are heatedusing, for example, a heater head having a notch, and thermally fused.

Subsequently, an electrolytic solution is injected through an opening inthe other side portion that is not thermally fused. Finally, thelaminate film 52 in the side portion through which the electrolyticsolution is injected is thermally fused, and the battery element 90 issealed in the laminate film 52. After that, heat pressing in which thebattery element 90 is pressurized and heated from the outside of thelaminate film 52 is carried out, and the electrolytic solution is heldin the porous polymer compound. Thereby, the electrolytic solutionholding layer 66 is formed. During the hot press, the porous polymercompound swells in the electrolytic solution holding layer 66, but thepore structure of the porous polymer compound is not collapsed, and thepores are maintained. Thereby, the non-aqueous electrolyte battery 81 iscompleted.

4. Fourth Embodiment

(Example of the Battery Pack)

FIG. 15 is a block diagram showing an example of the circuitconfiguration when the non-aqueous electrolyte battery of the technology(hereinafter referred to appropriately as the secondary battery) isapplied to a battery pack. The battery pack has an assembled battery101, an exterior, a switch section 104 having a charge control switch102 a and a discharge control switch 103 a, an electric currentdetecting resistance 107, a temperature detecting element 108, and acontrolling section 110.

In addition, the battery pack has a positive electrode terminal 121 anda negative electrode terminal 122, and, during charging, the positiveelectrode terminal 121 and the negative electrode terminal 122 areconnected to the positive electrode terminal and negative electrodeterminal in a charger, respectively, so that charging is carried out. Inaddition, during use of an electronic device, the positive electrodeterminal 121 and the negative electrode terminal 122 are connected tothe positive electrode terminal and negative electrode terminal in theelectronic device, respectively, so that discharging is carried out.

The assembled battery 101 is connected to a plurality of secondarybatteries 101 a in series and/or in parallel. The secondary battery 101a is the secondary battery of the technology. Meanwhile, FIG. 15 shows acase in which six secondary batteries 101 a are connected (two batteriesin parallel, three batteries in series (2P3S)) as an example, but may beconnected by any connecting method, such as n batteries in parallel andm batteries in series (n and m are integers).

The switch section 104 has the charge control switch 102 a, a diode 102b, the discharge control switch 103 a, and a diode 103 b, and iscontrolled by the controlling section 110. The diode 102 b has apolarity that is reverse for charging electric currents which flow in adirection from the positive electrode terminal 121 to the assembledbattery 101 and is forward for discharging electric currents which flowin a direction from the negative electrode terminal 122 to the assembledbattery 101. The diode 103 b has a polarity that is forward for thecharging electric currents and is reverse for the discharging electriccurrents. Furthermore, the switch section is provided on the positiveside in the example, but may be provided on the negative side.

The charge control switch 102 a is controlled by a charge and dischargesection so that the charge control switch is turned off when the batteryvoltage becomes an overcharge detecting voltage so as to preventcharging electric currents from flowing through the electric currentpassage of the assembled battery 101. After the charge control switch isturned off, only discharging through the diode 102 b becomes possible.In addition, the charge control switch is controlled by the controllingsection 110 so that the charge control switch is turned off when a largeelectric current flows during charging so as to block charging electriccurrents which flow through the electric current passage of theassembled battery 101.

The discharge control switch 103 a is controlled by the controllingsection 110 so that the discharge control switch is turned off when thebattery voltage becomes an over-discharge detecting voltage so as toprevent discharge electric currents from flowing through the electriccurrent passage of the assembled battery 101. After the dischargecontrol switch 103 a is turned off, only charging through the diode 103b becomes possible. In addition, the discharge control switch 103 a iscontrolled by the controlling section 110 so that the discharge controlswitch is turned off when a large electric current flows duringdischarging so as to block discharge electric currents which flowthrough the electric current passage of the assembled battery 101.

The temperature detecting element 108 is, for example, a thermistor,provided in the vicinity of the assembled battery 101, and measures thetemperature of the assembled battery 101 so as to supply the measuredtemperature to the controlling section 110. The voltage detectingsection 111 measures the voltages of the assembled battery 101 and therespective secondary batteries 101 a which compose the assembledbattery, A/D converts the measured voltages, and supplies the voltagesto the controlling section 110. The electric current measuring section113 measures an electric current using the electric current detectingresistance 107, and supplies the measured electric current to thecontrolling section 110.

The switch controlling section 114 controls the charge control switch102 a and the discharge control switch 103 a in the switch section 104based on voltages and electric currents entered from the voltagedetecting section 111 and the electric current measuring section 113.The switch controlling section 114 sends a control signal to the switchsection 104 when the voltage of any of the secondary batteries 101 abecomes the overcharge detecting voltage or the over-discharge detectingvoltage or less, or a large electric current abruptly flows so as toprevent overcharging, over discharging, and over electric currentcharging and discharging.

Here, for example, when the secondary battery is a lithium ion secondarybattery, the overcharge detecting voltage is specified as, for example,4.20 V±0.05 V, and the over discharge detecting voltage is specified as,for example 2.4 V±0.1 V.

As the charge and discharge switch, for example, a semiconductor switch,such as a MOSFET, can be used. In this case, the body diode of theMOSFET functions as the diode 102 b and the diode 103 b. When a Pchannel-type FET is used as the charge and discharge switch, the switchcontrolling section 114 supplies control signals DO and CO,respectively, to the respective gates of the charge control switch 102 aand the discharge control switch 103 a. When the charge control switch102 a and the discharge control switch 103 a are p channel-type, thecharge control switch 102 a and the discharge control switch 103 a areturned on by a gate potential that is a predetermined value or morelower than the source potential. That is, in an ordinary charge anddischarge operation, the control signals CO and DO are set to lowlevels, and the charge control switch 102 a and the discharge controlswitch 103 a are set to the ON state.

In addition, for example, in the case of overcharge and over discharge,the control signals CO and DO are set to high levels, and the chargecontrol switch 102 a and the discharge control switch 103 a are set tothe OFF state.

A memory 117 is composed of a RAM or ROM, and is composed of, forexample, an erasable programmable read only memory (EPROM) or the like,which is a nonvolatile memory. In the memory 117, numeric valuescomputed by the controlling section 110, the internal resistance valuesof the batteries in the initial states of the respective secondarybatteries 101 a, which are measured at the steps of the manufacturingprocess, and the like are stored in advance, and, appropriately,information alteration is also possible. In addition, storing the fullycharge capacities of the secondary batteries 101 a allows thecomputation of, for example, the remaining power in association with thecontrolling section 110.

The temperature detecting section 118 measures the temperature using thetemperature detecting element 108, controls charge and discharge in caseof abnormal heat generation, and corrects the computation of theremaining power.

5. Fifth Embodiment

The above non-aqueous electrolyte battery and the battery pack using thesame can be mounted on a device, such as an electronic device, anelectromotive vehicle, and a power storage apparatus, and used to supplyelectric power.

Examples of the electronic device include a notebook-type personalcomputer, a personal digital assistant (PDA), a mobile phone, a cordlessphone handset, a video movie, a digital still camera, an electronicbook, an electronic dictionary, a music player, a radio, a headphone, agame player, a navigation system, a memory card, a pacemaker, anacoustic aid, an electromotive tool, an electric absorber, arefrigerator, an air conditioner, a television, a stereo, a waterheater, a microwave, a dish washer, a washing machine, a drying machine,a lighting device, a toy, a medical device, a robot, a load conditioner,a traffic light, and the like.

In addition, the electromotive vehicle includes a railway vehicle, agolf cart, an electromotive cart, an electric vehicle (including ahybrid vehicle), and the like, and can be used as the driving powersupply or auxiliary power supply of the above.

The power storage apparatus includes power sources for electric powerstorage for constructions beginning with houses and power generationfacilities, and the like.

Hereinafter, among the above applications, a specific example of a powerstorage system in which a power storage apparatus to which thenon-aqueous electrolyte battery of the technology is applied is usedwill be described.

The power storage system has, for example, the following configuration.A first power storage system is a power storage system in which a powerstorage apparatus is charged by a power generation apparatus in whichpower generation is carried out from renewable energy. A second powerstorage system is a power storage system that has a power storageapparatus and supplies electric power to an electronic device connectedto the power storage apparatus. A third power storage system is anelectronic device that receives the supply of electric power from apower storage apparatus. These power storage systems are embodied assystems for supplying electric power efficiently in cooperation with anexternal power supply network.

Furthermore, a fourth power storage system is an electromotive vehiclehaving a converting apparatus that receives the supply of electric powerfrom a power storage apparatus and converts the electric power to thedriving force of a vehicle and a control apparatus that carries outinformation processing concerning the vehicle control based oninformation concerning the power storage apparatus. A fifth powerstorage system is an electric power system that has an electric powerinformation sending and receiving section that sends and receivessignals with other devices through a network and carries out the chargeand discharge control of the above power storage apparatus based oninformation received by the sending and receiving unit. A sixth powerstorage system is an electric power system that receives the supply ofelectric power from the above power storage apparatus or supplieselectric power to a power storage apparatus from a power generationapparatus or an electric power network. Hereinafter, the power storagesystem will be described.

(5-1) Power Storage System in a House as an Application

An example in which a power storage apparatus in which the non-aqueouselectrolyte battery of the technology is used is applied to a powerstorage system for a house will be described with reference to FIG. 16.For example, in a power storage system 200 for a house 201, electricpower is supplied to a power storage apparatus 203 from a centralizedelectric power system 202, such as thermal power generation 202 a,nuclear power generation 202 b, or hydroelectric power generation 202 c,through an electric power network 209, an information network 212, asmart meter 207, a power hub 208, or the like. Together with the above,electric power is supplied to the power storage apparatus 203 from anindependent power source, such as an in-house power generation apparatus204. The supplied electric power is stored in the power storageapparatus 203. Electric power used in the house 201 is supplied usingthe power storage apparatus 203. The same power storage system can beused not only for the house 201 but also for buildings.

The house 201 is provided with the power generation apparatus 204, apower consumption apparatus 205, the power storage apparatus 203, acontrol apparatus that controls the respective apparatuses 210, thesmart meter 207, and a sensor 211 that obtains a variety of information.The respective apparatuses are connected to each other by the electricpower network 209 and the information network 212. A solar cell, a fuelcell, or the like is used as the power generation apparatus 204, and thegenerated electric power is supplied to the power consumption apparatus205 and/or the power storage apparatus 203. The power consumptionapparatus 205 is a refrigerator 205 a, an air conditioner 205 b, atelevision receiver 205 c, a bath 205 d, or the like. Furthermore, thepower consumption apparatus 205 includes the electromotive vehicle 206.The electromotive vehicle 206 is an electric vehicle 206 a, a hybrid car206 b, and an electric bike 206 c.

The non-aqueous electrolyte battery is applied to the power storageapparatus 203. The non-aqueous electrolyte battery of the technology maybe composed of, for example, the above lithium ion secondary battery.The smart meter 207 has functions of measuring the used amount ofcommercial electric power and sending the measured used amount to anelectric power company. The electric power network 209 may be any ofdirect current power supply, alternative current power supply, andnon-contact power supply, or a combination of a plurality thereof.

Examples of the variety of sensors 211 include a motion sensor, anillumination sensor, an object-detecting sensor, a power consumptionsensor, a vibration sensor, a contact sensor, a temperature sensor, aninfrared sensor, and the like. Information obtained by the variety ofsensor 211 is sent to the control apparatus 210. The state of weather,the state of a person, and the like can be grasped from the informationfrom the sensor 211, and the power consumption apparatus 205 isautomatically controlled so that the energy consumption can beminimized. Furthermore, the control apparatus 210 can send informationconcerning the house 201 to an external electric power company or thelike through the internet.

The power hub 208 allows treatments, such as branching of electric powerlines, direct current-alternative current conversion, and the like. Thecommunication method of the information network 212 connected to thecontrol apparatus 210 includes a method in which a communicationinterface, such as universal asynchronous receiver-transceiver (UART),is used, and a method in which a sensor network according to thewireless communication standards, such as Bluetooth, ZigBee, and Wi-Fi,is used. The Bluetooth method can be applied to multimedia communicationso as to carry out one to multi communication. In ZigBee, a physicallayer of the Institute of Electrical and Electronics Engineers (IEEE)802.15.4 is used. The IEEE 802.15.4 is the title of the short-distancewireless network standard called a personal area network (PAN) or awireless PAN.

The control apparatus 210 is connected to an external server 213. Theserver 213 may be managed by any of the house 201, an electric powercompany, and a service provider. The information sent by the server 213is, for example, power consumption information, life patterninformation, electric power fees, weather information, natural disasterinformation, or information concerning electricity transactions. Thisinformation may be sent and received by a power consumption apparatus ina house (for example, a television receiver), but also may be sent andreceived by an apparatus in a house (for example, a mobile phone or thelike). This information may be displayed on a device having a displayfunction, such as a television receiver, a mobile phone, and a personaldigital assistant (PDA).

The control apparatus 210 that controls the respective units is composedof a central processing unit (CPU), a random access memory (RAM), a readonly memory (ROM), and the like, and is accommodated in the powerstorage apparatus 203 in this example. The control apparatus 210 isconnected to the power storage apparatus 203, the in-house powergeneration apparatus 204, the power consumption apparatus 205, thevariety of sensors 211, and the server 213 by the information network212, and has functions of adjusting the used amount of commercialelectric power and the power generation amount. Meanwhile, in additionto those functions, the control apparatus 210 may have a function ofcarrying out electricity transactions in an electric power market, andthe like.

As described above, it is possible to store electric power generated bythe in-house power generation apparatus 204 (solar photovoltaic powergeneration and wind power generation) as well as electric powergenerated by the centralized electric power system 202, such as thermalpower generation 202 a, nuclear power generation 202 b, or hydroelectricpower generation 202 c, in the power storage apparatus 203. Therefore,even when the electric power generated by the in-house power generationapparatus 204 varies, it is possible to carry out the control of keepingthe amount of electric power sent outside constant or discharging asmuch as necessary. For example, the power storage system can be used notonly to store electric power obtained by solar photovoltaic powergeneration in the power storage apparatus 203, but also to storenighttime electric power for which the fees are cheap in the powerstorage apparatus 203 during the nighttime and discharge the electricpower stored by the power storage apparatus 203 during daytime in whichthe fees are expensive.

Meanwhile, this example describes an example in which the controlapparatus 210 is accommodated in the power storage apparatus 203, butthe control apparatus 210 may be accommodated in the smart meter 207 orconfigured singly. Furthermore, the power storage system 200 may be usedfor a plurality of houses in a housing complex, or used for a pluralityof detached houses.

(5-2) Power Storage System in a Vehicle as an Application

An example in which the technology is applied to a power storage systemfor vehicle will be described with reference to FIG. 17. FIG. 17schematically shows an example of the configuration of a hybrid vehiclein which a series hybrid system to which the technology is applied isemployed. The series hybrid system is a vehicle that uses electric powergenerated by a power generator which is operated by an engine orelectric power temporarily stored in a battery so as to run an electricpower to driving force converting apparatus.

The hybrid vehicle 300 includes an engine 301, a power generator 302, anelectric power to driving force converting apparatus 303, a drivingwheel 304 a, a driving wheel 304 b, a wheel 305 a, a wheel 305 b, abattery 308, a vehicle controlling apparatus 309, a variety of sensors310, and a charging opening 311. The non-aqueous electrolyte battery ofthe technology is applied to the battery 308.

The hybrid vehicle 300 runs using the electric power to driving forceconverting apparatus 303 as a power source. An example of the electricpower to driving force converting apparatus 303 is a motor. The electricpower to driving force converting apparatus 303 is operated by theelectric power of the battery 308, and a rotative force of the electricpower to driving force converting apparatus 303 is transmitted to thedriving wheels 304 a and 304 b. Meanwhile, use of direct current toalternative current (DC-AC) conversion or alternative current to directcurrent (AC-DC) conversion allows the application of the electric powerto driving force converting apparatus 303 to both an alternative currentmotor and a direct current motor. The variety of sensors 310 controlsthe rotation number of the engine through the vehicle controllingapparatus 309 or controls the opening of a throttle valve (throttlevalve). The variety of sensors 310 includes a speed sensor, anacceleration sensor, an engine rotation number sensor, and the like.

The rotative force of the engine 301 is transmitted to the powergenerator 302, and electric power generated by the power generator 302can be stored in the battery 308 due to the rotative force.

When the hybrid vehicle 300 is decelerated by a damping mechanism, notshown, the resistive force generated during the deceleration is added tothe electric power to driving force converting apparatus 303 as arotative force, and the regenerative electric power generated by theelectric power to driving force converting apparatus 303 is stored inthe battery 308 due to the rotative force.

When the battery 308 is connected to an external power source of thehybrid vehicle 300, the battery can receive the supply of electric powerfrom the external power source through the charging opening 311 as anentering opening, and store the received electric power.

Although not shown, the hybrid vehicle may have an informationprocessing apparatus that carries out information processing concerningvehicle control based on information concerning the secondary battery.Examples of the information processing apparatus include an informationprocessing apparatus that displays the remaining amount of the batterybased on information concerning the remaining amount of the battery.

Meanwhile, in the above, an example of a series hybrid vehicle isdescribed that uses electric power generated by the power generatorwhich is operated by the engine or electric power temporarily stored inthe battery so as to run by the motor. However, the technology can beeffectively applied to a parallel hybrid vehicle that appropriatelyswitches and uses three methods in which any of the engine and the motoris used as a driving source, and the vehicle runs by only the engine,only the motor, and the engine and the motor. Furthermore, thetechnology can also be effectively applied to a so-called electromotivevehicle that does not use an engine and runs by the driving only of thedriving motor.

EXAMPLES

Hereinafter, the technology will be described specifically usingexamples, but the technology is not limited only to the examples.Meanwhile, the weight average molecular weight and degree of swelling ofa polymer material used in the following samples were measured in thefollowing manner.

(Measurement of the Weight Average Molecular Weight)

The weight average molecular weight of the polymer material was measuredby the following method. Gel permeation chromatography (GPC)manufactured by Showa Denko K.K. (product name: Shodex GPC-101) wasused, in which Shodex RI-71S (product name) manufactured by Showa DenkoK.K., N-methyl-2-pyrrolidone (NMP), and Shodex GPC KD-860M (productname) manufactured by Showa Denko K.K. were used as a detector, aneluent, and a packed column, respectively. A calibration curve, in whichthe correlation between the detecting duration and the molecular weightwas obtained using standard polystyrene, was obtained in advance, andthe measurement of the polymer material was carried out under the sameconditions, thereby obtaining a polystyrene-converted weight averagerelative molecular weight.

(Test of the Degree of Swelling)

The polymer material was dissolved in N-methyl-2-pyrrolidone, coated ona glass substrate using a coater, left to stand at 90° C. for one hour,dried by heating at 60° C. under a vacuum for 24 hours or more, and theN-methyl-2-pyrrolidone was removed, thereby obtaining a single film. Theobtained film was punched into a disk shape of 20 mmφ, immersed in asolvent of 60° C. for 24 hours, and the degree of swelling, or {[volumeafter immersion]/[volume before immersion]}×100 (%), was obtained fromthe change in the volume before and after the immersion.

<Sample 1-1>

A laminate-type battery shown in FIGS. 1 and 2 was manufactured in thefollowing manner.

(Manufacturing of the Positive Electrode)

85 parts by mass of lithium cobaltate (LiCoO₂), 5 parts by mass ofgraphite, which is a conducting agent, and 10 parts by mass ofpolyvinylidene fluoride, which is a bonding agent, were mixed so as toprepare a positive electrode compound, and, furthermore, the positiveelectrode compound was dispersed in N-methyl-2-pyrrolidone, which is adispersion medium, so as to produce a positive electrode compoundslurry.

Subsequently, the positive electrode compound slurry was evenly coatedand dried on both surfaces of the positive electrode collector 33Acomposed of a 20 μm-thick aluminum foil, and then compacted using a rollpress machine so as to form the positive electrode active material layer33B, thereby manufacturing the positive electrode 33. After that, thepositive electrode lead 31 was attached to the positive electrode 33.

(Manufacturing of the Negative Electrode)

Crushed graphite powder was prepared as a negative electrode activematerial, 90 parts by mass of the graphite powder and 10 parts by massof polyvinylidene fluoride, which is a bonding agent, was mixed so as toprepare a negative electrode compound, and, furthermore, the negativeelectrode compound was dispersed in N-methyl-2-pyrrolidone, which was adispersion medium, so as to produce a negative electrode compoundslurry.

Next, the negative electrode compound slurry was evenly coated and driedon both surfaces of the negative electrode collector 34A composed of a15 μm-thick copper foil, and then compacted using a roll press machineso as to form the negative electrode active material layer 34B, therebymanufacturing the negative electrode 34. At that time, the ratio of thecapacity of the positive electrode 33 with respect to the capacity ofthe negative electrode 34 was set to 1.1. Subsequently, the negativeelectrode lead 32 was attached to the negative electrode 34.

(Manufacturing of the Porous Polymer Compound)

A polymer material was dissolved in N-methyl-2-pyrrolidone so as toprepare a solution. The solution was coated on both surfaces of theseparator 35, immersed in water, and then dried. Thereby, a porouspolymer compound having a porous structure was formed on both surfacesof the separator 35. A polyethylene microporous film (air permeabilityof 200 seconds/100 cc) was used as the separator 35.

The following vinylidene fluoride polymer was used as the polymermaterial.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=97:7

Weight average molecular weight: 350,000

The positive electrode 33 and the negative electrode 34 were closelyadhered through the separator 35 having the porous polymer compoundformed on both surfaces, then wound in the longitudinal direction, andthe protective tape 37 was attached to the outermost circumference,thereby manufacturing the wound electrode body 30.

The wound electrode body 30 was interposed in the exterior member 40,and three sides were thermally fused. Meanwhile, a damp-proof aluminumlaminate film having a structure in which a 25 μm-thick nylon film, a 40μm-thick aluminum foil, and a 30 μm-thick polypropylene film werelaminated sequentially from the outermost layer was used as the exteriormember 40.

After that, an electrolytic solution was injected into the exteriormember so that the amount of the electrolytic solution in the cellbecame 1.85 g, and the remaining side was thermally fused under areduced pressure, whereby the exterior member was sealed. A solution oflithium hexafluorophosphate (LiPF₆) dissolved in a mixed solvent ofethylene carbonate (EC) and diethyl carbonate (DEC) at a concentrationof 1.2 mol/l was used as the electrolytic solution. In addition, theexterior member was interposed between iron plates and heated at 100° C.for 3 minutes so that the positive electrode 33, the negative electrode34, and the separator 35 were adhered through the electrolytic solutionholding layer 36. Thereby, a laminate film-type battery having a size of4×35×50 mm (7 cm³) as shown in FIGS. 1 and 2 was obtained.

<Sample 1-2>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=97:3

Weight average molecular weight: 500,000

The laminate film-type battery of Sample 1-2 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-3>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=97:3

Weight average molecular weight: 750,000

The laminate film-type battery of Sample 1-3 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-4>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=97:3

Weight average molecular weight: one million

The laminate film-type battery of Sample 1-4 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-5>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=95:5

Weight average molecular weight: 350,000

The laminate film-type battery of Sample 1-5 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-6>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=95:5

Weight average molecular weight: 500,000

The laminate film-type battery of Sample 1-6 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-7>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=95:5

Weight average molecular weight: 750,000

The laminate film-type battery of Sample 1-7 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-8>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=95:5

Weight average molecular weight: one million

The laminate film-type battery of Sample 1-8 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-9>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=93:7

Weight average molecular weight: 350,000

The laminate film-type battery of Sample 1-9 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-10>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=93:7

Weight average molecular weight: 500,000

The laminate film-type battery of Sample 1-10 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-11>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=93:7

Weight average molecular weight: 750,000

The laminate film-type battery of Sample 1-11 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-12>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=93:7

Weight average molecular weight: one million

The laminate film-type battery of Sample 1-12 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-13>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride homopolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=100:0

Weight average molecular weight: 350,000

The laminate film-type battery of Sample 1-13 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-14>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride homopolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=100:0

Weight average molecular weight: 500,000

The laminate film-type battery of Sample 1-14 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-15>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride homopolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=100:0

Weight average molecular weight: 750,000

The laminate film-type battery of Sample 1-15 was manufactured in thesame manner as in Sample 1-1 except the above.

<Sample 1-16>

The following vinylidene fluoride polymer was used as the polymermaterial when the porous polymer compound was manufactured.

Polymer material: vinylidene fluoride homopolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=100:0

Weight average molecular weight: one million

The laminate film-type battery of Sample 1-16 was manufactured in thesame manner as in Sample 1-1 except the above.

(Evaluation)

The following evaluations were carried out on the laminate film-typebatteries of Sample 1-1 to Sample 1-16.

(Test of the Separation Strength between the Negative Electrode and theSeparator)

The laminate film-type batteries of Sample 1-1 to Sample 1-16 werecharged and discharged once, disassembled, and the separation strengthbetween the negative electrode and the separator was measured at a rateof 100 mm/minute in a tension test.

(Measurement of the Air Permeability of the Porous Polymer Compoundbefore Heat Pressing and after Heat Pressing)

The air resistance (air permeability) was measured using a Gurley-typeair permeability meter according to JIS P-817. The measured film areawas 6.45 cm², the permeated air amount was set to 100 cc, and theduration at that time was used as the air permeability (second/100 cc).

(Measurement of the Capacity Retention Rate after 300 Cycles)

Firstly, on each of the batteries, under conditions of 25° C., constantcurrent constant voltage charging of 500 mA was carried out until anupper limit voltage of 4.2 V and 3 hours, and then constant currentdischarging of 160 mA was carried out until a final voltage of 3 V.

Next, constant current charging of 1000 mA was carried out until anupper limit voltage of 4.2 V, and then constant voltage charging wascarried out until the cutoff current became 50 mA or until the durationof constant voltage charging reached 3 hours. Constant currentdischarging of 800 mA was carried out until a final voltage of 3 V, andthe discharge capacity at this time was measured and used as thedischarge capacity at the first cycle.

After that, charging and discharging were repeated 299 times under thesame charging and discharging conditions, and the discharge capacity atthe 300^(th) cycle was measured. In addition, the discharge capacity atthe 300^(th) cycle under an assumption that the discharge capacity atthe 1^(st) cycle was 100 was obtained as the capacity retention rateafter the 300^(th) cycle, or {discharge capacity at 300^(th)cycle/discharge capacity at 1^(st) cycle}×100 (%).

(Observation by a Scanning Electron Microscope (SEM))

The laminate film-type batteries of Sample 1-4 and Sample 1-10 weredisassembled, and the electrolytic solution holding layers 36 formed onthe separators 35 were observed using a SEM. The SEM photograph ofSample 1-4 is shown in FIG. 18, and the SEM photograph of Sample 1-10 isshown in FIGS. 19 and 21.

The evaluation results are shown in Table 1.

TABLE 1 Vinylidene fluoride polymer Separation strength Air Air CapacityWeight average Mass composition ratio between negative permeabilitypermeability retention molecular weight Vinylidene Hexafluoro- Degree ofelectrode and before heat after heat rate after [ten fluoride propyleneswelling separator pressing pressing 300 cycles thousands] monomer unitmonomer unit [%] [N/m] [sec/100 cc] [sec/100 cc] [%] Sample 1-1 35 97 3110 5 489 502 70 Sample 1-2 50 106 10 248 277 85 Sample 1-3 75 105 11242 286 84 Sample 1-4 100 106 13 237 256 86 Sample 1-5 35 95 5 121 3470 >10000 38 Sample 1-6 50 123 12 247 289 80 Sample 1-7 75 122 12 235298 78 Sample 1-8 100 120 13 229 278 82 Sample 1-9 35 93 7 136 4509 >10000 32 Sample 1-10 50 133 15 247 6712 39 Sample 1-11 75 133 14249 6210 38 Sample 1-12 100 134 15 229 5400 34 Sample 1-13 35 100 — 1035 468 498 71 Sample 1-14 50 102 10 287 289 82 Sample 1-15 75 102 10 268294 81 Sample 1-16 100 103 10 276 288 81

As shown in Table 1, in Sample 1-2 to Sample 1-4, Sample 1-6 to Sample1-8, and Sample 1-14 to Sample 1-16, the capacity retention rate afterthe 300^(th) cycle was favorable, and the air permeability of the porouspolymer compound after heat pressing was also small.

On the other hand, in Sample 1-1, Sample 1-5, Sample 1-9, and Sample1-13, since the weight average molecular weight of the polymer compoundwas smaller than the optimal value, or 500,000, the separation strengthbetween the negative electrode and the separator was degraded, wherebythe capacity retention rate after the 300^(th) cycle was degraded. Inaddition, the air permeability of the porous polymer compound after heatpressing was also slightly large.

In addition, in Sample 1-9 to Sample 1-12, since the mass compositionratio of the vinylidene fluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, was outside a range of 100:0 to95:5, the air permeability of the porous polymer compound after heatpressing was large. This is because, like Sample 1-10 shown in FIGS. 19and 21, when the mass composition ratio of the vinylidene fluoridepolymer, or vinylidene fluoride monomer units:hexafluoropropylenemonomer units, was outside a range of 100:0 to 95:5, the porous polymercompound excessively swelled during heat pressing, and therefore thepore structure was collapsed, and the pores were closed. In addition, inSample 1-9 to Sample 1-12, since the degree of swelling of thevinylidene fluoride polymer was excessively increased, and thevinylidene fluoride polymer was dissolved in the electrolytic solution,the capacity retention rate after the 300^(th) cycle was also degraded.Meanwhile, like Sample 1-4 shown in FIGS. 18 and 20, when the masscomposition ratio of the vinylidene fluoride polymer, or vinylidenefluoride monomer units:hexafluoropropylene monomer units, was within arange of 100:0 to 95:5, the porous polymer compound did not swellexcessively, and the pore structure was maintained during heat pressing,and therefore the air permeability was small.

<Sample 2-1>

A laminate film-type battery shown in FIGS. 1 and 2 was manufactured inthe following manner.

(Manufacturing of the Positive Electrode, Manufacturing of the NegativeElectrode)

The positive electrode 33 and the negative electrode 34 weremanufactured in the same manner as in Sample 1-1, the positive electrodelead 31 was attached to the positive electrode 33, and the negativeelectrode lead 32 was attached to the negative electrode 34.

(Manufacturing of the Porous Polymer Compound)

A solution containing inorganic particles dispersed inN-methyl-2-pyrrolidone was added to a solution containing a polymermaterial dissolved in N-methyl-2-pyrrolidone so as to prepare asolution. The solution was coated on both surfaces of the separator 35,immersed in water, and then dried. Thereby, a porous polymer compoundcontaining the inorganic particles and having a porous structure wasformed on both surfaces of the separator 35. A polyethylene microporousfilm (air permeability of 200 seconds/100 cc) was used as the separator35.

The following material was used as the polymer material when the porouspolymer compound was manufactured.

Polymer material: vinylidene fluoride—hexafluoropropylene copolymer

Mass composition ratio (vinylidene fluoride monomerunit:hexafluoropropylene monomer unit)=97:3

Weight average molecular weight: one million

The following material was used as the inorganic particles.

Inorganic particles: alumina (average particle diameter of 0.45 μm)

Polymer material: inorganic particles (mass ratio)=1:2

The positive electrode 33 and the negative electrode 34 were closelyadhered through the separator 35 having the porous polymer compoundcontaining the inorganic particles formed on both surfaces, then woundin the longitudinal direction, and the protective tape 37 was attachedto the outermost circumference, thereby manufacturing the woundelectrode body 30.

The wound electrode body 30 was interposed in the exterior member 40,and three sides were thermally fused. Meanwhile, a damp-proof aluminumlaminate film having a structure in which a 25 μm-thick nylon film, a 40μm-thick aluminum foil, and a 30 μm-thick polypropylene film werelaminated sequentially from the outermost layer was used as the exteriormember 40.

After that, an electrolytic solution was injected into the exteriormember so that the amount of the electrolytic solution in the cellbecame 1.85 g, and the remaining side was thermally fused under areduced pressure, whereby the exterior member was sealed. A solution oflithium hexafluorophosphate (LiPF₆) dissolved in a mixed solvent ofethylene carbonate (EC) and diethyl carbonate (DEC) at a concentrationof 1.2 mol/l was used as the electrolytic solution. In addition, theexterior member was interposed between iron plates and heated at 100° C.for 3 minutes so that the positive electrode 33, the negative electrode34, and the separator 35 were adhered through the electrolytic solutionholding layer 36. Thereby, a laminate film-type battery having a size of4×35×50 mm (7 cm³) as shown in FIGS. 1 and 2 was obtained. The thicknessof the electrolytic solution holding layer 36 was adjusted to 3.1 μm,and the area density was adjusted to 0.28 mg/cm².

Meanwhile, in order to remove the influence of the thickness of theelectrolytic solution holding layer 36, for Samples 2-2 to 2-5 as shownbelow, for which the content ratios of alumina were different from thatof Sample 2-1, the area density was adjusted so that the thickness ofthe electrolytic solution holding layer 36 was set to around 3 μm.

<Sample 2-2>

In the manufacturing of the porous polymer compound, the mass ratio ofthe polymer material to the inorganic particles was changed to thepolymer material:the inorganic particles (mass ratio)=1:4. The thicknessof the electrolytic solution holding layer 36 was adjusted to 3.3 μm,and the area density was adjusted to 0.35 mg/cm². A laminate film-typebattery was manufactured in the same manner as in Sample 2-1 except theabove.

<Sample 2-3>

In the manufacturing of the porous polymer compound, the mass ratio ofthe polymer material to the inorganic particles was changed to thepolymer material:the inorganic particles (mass ratio)=1:6. The thicknessof the electrolytic solution holding layer 36 was adjusted to 2.9 μm,and the area density was adjusted to 0.41 mg/cm². A laminate film-typebattery was manufactured in the same manner as in Sample 2-1 except theabove.

<Sample 2-4>

In the manufacturing of the porous polymer compound, the mass ratio ofthe polymer material to the inorganic particles was changed to thepolymer material:the inorganic particles (mass ratio)=1:8. The thicknessof the electrolytic solution holding layer 36 was adjusted to 3.0 μm,and the area density was adjusted to 0.45 mg/cm². A laminate film-typebattery was manufactured in the same manner as in Sample 2-1 except theabove.

<Sample 2-5>

In the manufacturing of the porous polymer compound, the mass ratio ofthe polymer material to the inorganic particles was changed to thepolymer material:the inorganic particles (mass ratio)=1:10. Thethickness of the electrolytic solution holding layer 36 was adjusted to3.1 μm, and the area density was adjusted to 0.51 mg/cm². A laminatefilm-type battery was manufactured in the same manner as in Sample 2-1except the above.

(Evaluation)

The following evaluation was carried out on the laminate film-typebatteries of Sample 2-1 to Sample 2-5. Meanwhile, the float test wasalso carried out on Sample 1-4 in addition to Sample 2-1 to Sample 2-5.

(Test of the Separation Strength between the Negative Electrode and theSeparator) and (Measurement of the Capacity Retention Rate after 300Cycles)

The test of the separation strength between the negative electrode andthe separator and the measurement of the capacity retention rate after300 cycles were carried out in the same manner as in Sample 1-1.

(Float Test)

In a constant temperature bath set to 60° C., constant current chargingwas carried out on the laminate film-type battery by a constant currentof 1000 mA until the battery voltage reached 4.25 V, and then constantvoltage charging was carried out at 4.25 V. At this time, the durationin which the change in the charging current was observed (leakedelectric currents occurred) was obtained.

The evaluation results of Sample 2-1 to Sample 2-5 are shown in Table 2.Meanwhile, the evaluation results of (the test of the separationstrength between the negative electrode and the separator) and (themeasurement of the capacity retention rate after 300 cycles) of Sample1-4 shown in Table 1 and the evaluation results of the float test ofSample 1-4 are also shown in Table 2 for comparison.

TABLE 2 Capacity Duration until leaked Thickness of Separation strengthretention electric current is Vinylidene fluoride Area electrolyticbetween negative rate after observed with float polymer:alumina densitysolution holding electrode and 300 cycles charging at 60° C. (massratio) [mg/cm²] layer [μm] separator [N/m] [%] and 4.25 V [h] Sample 1-41:0 0.15 3.2 13 86 200 Sample 2-1 1:2 0.28 3.1 10 88 260 Sample 2-2 1:40.35 3.3 8 89 313 Sample 2-3 1:6 0.41 2.9 5 85 320 Sample 2-4 1:8 0.453.0 5 80 340 Sample 2-5  1:10 0.51 3.1 2 55 380

As shown in Table 2, with the mass ratio of the vinylidene fluoridepolymer and the alumina in a range of 1:0 to 1:8, the “separationstrength between the negative electrode and the separator” was 5 N/m ormore, and the capacity retention rate after 300 cycles was also 80% ormore, which was preferable. On the other hand, when the mass ratio ofthe vinylidene fluoride polymer and the alumina became 1:10, there was atendency that the separation strength between the negative electrode andthe separator also became 2 N/m, and the capacity retention rate after300 cycles was also degraded to 55%. In addition, it could be confirmedthat as the fraction of the alumina was increased in the mass ratio ofthe vinylidene fluoride polymer and the alumina, the duration, in whichleaked electric current was observed with float charging at 60° C. and4.25 V, was increased and the float resistance was also improved. Inconsideration of the above facts, a conclusion was made that, in theelectrolytic solution holding layer, the inorganic particles may beadded to the vinylidene fluoride polymer, and, in this case, the massratio of the vinylidene fluoride polymer to the inorganic particles ispreferably in a range of 1:1 to 1:8, and more preferably in a range of1:2 to 1:6.

6. Other Embodiment (an Example of Variation)

The technology is not limited to the above embodiments of thetechnology, and a variety of variations or applications are allowedwithin the scope of the gist of the technology. For example, the aboveembodiments and examples described batteries having the laminatefilm-type battery structure, batteries having a wound structure in whichelectrodes are wound, and stack-type batteries having a laminatestructure in which electrodes are laminated, but the technology is notlimited thereto. For example, the technology can also be applied tobatteries and the like having electrode structures or battery structuresother than the above battery structure or electrode structure. Thenon-aqueous electrolyte battery of the second embodiment may have aconfiguration in which the positive electrode lead 53 and the negativeelectrode lead 54 are drawn out from the same side may be employed. Thenon-aqueous electrolyte battery of the third embodiment may have aconfiguration in which the positive electrode lead 53 and the negativeelectrode lead 54 are drawn out from mutually facing sides. In addition,the second embodiment has a configuration in which the outermost layerof the battery element 60 forms the separator 63, but may have aconfiguration in which the outermost layer forms the positive electrode61 or the negative electrode 62. In addition, the second embodiment mayhave a configuration in which one outermost layer of the battery element60 forms the separator 63, and the other outermost layer forms thepositive electrode 61 or the negative electrode 62. The third embodimenthas a configuration in which the outermost layer of the battery element90 forms the negative electrode 62, but may have a configuration inwhich the outermost layer forms the separator 63 or the positiveelectrode 61. In addition, the third embodiment may have a configurationin which one outermost layer of the battery element 90 forms theseparator 63, and the other outermost layer forms the positive electrode61 or the negative electrode 62. The configuration of the laminate film52 in the second and third embodiments may be applied to the exteriormember 40 in the first embodiment.

In the above second and third embodiments and the examples of variationthereof, a porous polymer compound layer may be provided between thebattery element 60 and the laminate film 52. The porous polymer compoundlayer is configured by holding a non-aqueous electrolytic solution in apolymer material. A polymer material including vinylidene fluoride as acomponent is used as the polymer material. Specific examples that can bepreferably used include polyvinylidene fluoride (PVdF), copolymersincluding vinylidene fluoride (VdF) and hexafluoropropylene (HFP) asrepeating units, copolymers including vinylidene fluoride (VdF),hexafluoropropylene (HFP), and chlorotrifluoroethylene (CTFE) asrepeating units, and the like.

When polyvinylidene fluoride (PVdF) is used as the polymer material thatcomposes the porous polymer compound layer, it is preferable to usepolyvinylidene fluoride having a weight average molecular weight of500,000 or more to 1.5 million or less. This is because the effect ofsuppressing the movement of the battery element is high.

In addition, inorganic particles may be mixed into the porous polymercompound layer. The strength of the porous polymer compound layer isimproved, and recesses and protrusions are generated on the porouspolymer compound layer so that deviation between the battery element andthe laminate film can be suppressed. Therefore, an increase in theinternal resistance can be further suppressed.

The inorganic particles include metallic oxides, metallic nitrides,metallic carbides, and the like, all of which have electrical insulatingproperties. The metallic oxides that can be preferably used includealumina (Al₂O₃), magnesia (MgO), titania (TiO₂), zirconia (ZrO₂), silica(SiO₂), and the like. The metallic nitrides that can be preferably usedinclude silicon nitride (Si₃N₄), aluminum nitride (AlN), boron nitride(BN), titanium nitride (TiN), and the like. The metallic carbides thatcan be preferably used include silicon carbide (SiC), boron carbide(B₄C), and the like. These inorganic particles may be used singly or incombination of two or more kinds In addition, since the inorganicparticles are excellent in terms of heat resistance and oxidationresistance, the effect of suppressing the movement of the batteryelement is not impaired even during an increase in the batterytemperature, which is preferable.

In addition, the technology can employ the following configurations.

[1]

A non-aqueous electrolyte battery, having:

a positive electrode,

a negative electrode,

an insulating layer present between the positive electrode and thenegative electrode, and

an electrolytic solution holding layer that composes the insulatinglayer and includes an electrolytic solution and a porous polymercompound,

in which the electrolytic solution is held in the pores in the porouspolymer compound and swells the porous polymer compound,

the material of the porous polymer compound includes a vinylidenefluoride polymer,

the vinylidene fluoride polymer is a vinylidene fluoride homopolymer ora copolymer including vinylidene fluoride monomer unit and ahexafluoropropylene monomer unit,

the mass composition ratio of the monomer units of the vinylidenefluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and

the weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million.

[2]

The non-aqueous electrolyte battery according to [1],

in which the insulating layer is composed of a porous base materiallayer and

the electrolytic solution holding layer formed on at least one surfaceof the porous base material layer.

[3]

The non-aqueous electrolyte battery according to [1] or [2],

in which the air permeability of the porous polymer compound is 500seconds/100 cc or less.

[4]

The non-aqueous electrolyte battery according to [2] or [3],

in which the porous base material layer includes a porouspolyolefin-based resin.

[5]

The non-aqueous electrolyte battery according to any one of [1] to [4],

in which the weight average molecular weight of the vinylidene fluoridepolymer is 750,000 or more to less than 1.5 million.

[6]

The non-aqueous electrolyte battery according to any one of [1] to [5],

in which the air permeability of the porous polymer compound is 300seconds/100 cc or less.

[7]

The non-aqueous electrolyte battery according to any one of [1] to [6],

in which the electrolytic solution holding layer further includesinorganic particles, and the mass ratio of the vinylidene fluoridepolymer and the inorganic particles, or mass of the vinylidene fluoridepolymer:mass of the inorganic particles, is 1:1 to 1:10.

[8]

The non-aqueous electrolyte battery according to any one of [2] to [7],

in which the porous polymer compound is formed by coating a solutioncontaining the vinylidene fluoride polymer dissolved in a first solventcomposed of a polar organic solvent on a porous base material andimmersing the coated porous base material in a second solvent, which iscompatible with the first solvent and is a poor solvent with respect tothe polymer material.

[9]

The non-aqueous electrolyte battery according to any one of [1] to [8]comprising a laminated filmed exterior body.

[10]

A method of manufacturing a non-aqueous electrolyte battery

having a process in which a solution containing a polymer materialdissolved in a first solvent composed of a polar organic solvent iscoated on a porous base material, the coated porous base material isimmersed in a second solvent, the second solvent being compatible withthe first solvent and is a poor solvent with respect to the polymermaterial, thereby forming a porous polymer compound on the porous basematerial;

a process in which an electrode body having the positive electrode, thenegative electrode, and the porous base material on which the porouspolymer compound is formed, in which the porous base material on whichthe porous polymer compound is formed being present between the positiveelectrode and the negative electrode, is manufactured; and

a process in which the electrode body is accommodated in an exteriorbody, an electrolytic solution is injected into the exterior body, andthen heat pressing is carried out.

the polymer material including a vinylidene fluoride polymer, which is avinylidene fluoride homopolymer or a copolymer including a vinylidenefluoride monomer unit and a hexafluoropropylene monomer unit,

the mass composition ratio of the monomer units of the vinylidenefluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and

the weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million.

[11]

The method of manufacturing a non-aqueous electrolyte battery accordingto [10],

in which the first solvent is N-methyl-2-pyrrolidone, γ-butyrolactone,N,N-dimethylacetamide, or N,N-dimethyl sulfoxide and

the second solvent is water, ethyl alcohol, or propyl alcohol.

[12]

An insulating material, including a porous polymer compound,

in which the porous polymer compound can hold an electrolytic solutionin the pores, and can be swollen by the electrolytic solution,

the material of the porous polymer compound includes a vinylidenefluoride polymer,

the vinylidene fluoride polymer is a vinylidene fluoride homopolymer ora copolymer including a vinylidene fluoride monomer unit and ahexafluoropropylene monomer unit,

the mass composition ratio of the monomer units of the vinylidenefluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and

the weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million.

[13]

The insulating material according to [12], further including a porousbase material having the porous polymer compound formed on at least onesurface.

[14]

A method of manufacturing an insulating material including a porouspolymer compound, having:

a process in which a solution containing a polymer material dissolved ina first solvent composed of a polar organic solvent is coated on a basematerial, the base material coated with the solution is immersed in asecond solvent, which is compatible with the first solvent and is a poorsolvent with respect to the polymer material, thereby forming the porouspolymer compound,

in which the polymer material includes a vinylidene fluoride polymer,

the vinylidene fluoride polymer is a vinylidene fluoride homopolymer ora copolymer including a vinylidene fluoride monomer unit and ahexafluoropropylene monomer unit,

the mass composition ratio of the monomer units of the vinylidenefluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and

the weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million.

[15]

A battery pack, having:

the non-aqueous electrolyte battery according to any one of [1] to [9],

a controlling section that controls the non-aqueous electrolyte battery,and

an exterior that covers the non-aqueous electrolyte battery.

[16]

An electronic device having the non-aqueous electrolyte batteryaccording to any one of [1] to [9], and

receiving the supply of electric power from the non-aqueous electrolytebattery.

[17]

An electromotive vehicle, having:

the non-aqueous electrolyte battery according to any one of [1] to [9],

a converting apparatus that receives the supply of electric power fromthe non-aqueous electrolyte battery and converts the electric power to adriving force of the vehicle, and a control apparatus that carries outinformation processing concerning vehicle control based on informationconcerning the non-aqueous electrolyte battery.[18]

A power storage apparatus having the non-aqueous electrolyte batteryaccording to any one of [1] to [9], and supplying electric power to anelectronic device connected to the non-aqueous electrolyte battery.

[19]

The power storage apparatus according to [18] having an electric powerinformation control apparatus that sends and receives signals to andfrom other devices through a network and carrying out the charging anddischarging control of the non-aqueous electrolyte battery based oninformation received by the electric power information controlapparatus.

[20]

An electric power system which receives the supply of electric powerfrom the non-aqueous electrolyte battery according to any one of [1] to[9] or in which electric power is supplied to the non-aqueouselectrolyte battery from a power generating apparatus or an electricpower network.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope and without diminishing itsintended advantages. It is therefore intended that such changes andmodifications be covered by the appended claims.

1. A non-aqueous electrolyte battery comprising: a positive electrode, anegative electrode, an insulating layer present between the positiveelectrode and the negative electrode, and an electrolytic solutionholding layer that composes the insulating layer and includes anelectrolytic solution and a porous polymer compound, wherein theelectrolytic solution is held in the pores in the porous polymercompound and swells the porous polymer compound, the material of theporous polymer compound includes a vinylidene fluoride polymer, thevinylidene fluoride polymer is a vinylidene fluoride homopolymer or acopolymer including vinylidene fluoride monomer unit and ahexafluoropropylene monomer unit, the mass composition ratio of themonomer units of the vinylidene fluoride polymer, or vinylidene fluoridemonomer units:hexafluoropropylene monomer units is 100:0 to 95:5, andthe weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million.
 2. The non-aqueouselectrolyte battery according to claim 1, wherein the insulating layeris composed of a porous base material layer and the electrolyticsolution holding layer formed on at least one surface of the porous basematerial layer.
 3. The non-aqueous electrolyte battery according toclaim 1, wherein the air permeability of the porous polymer compound is500 seconds/100 cc or less.
 4. The non-aqueous electrolyte batteryaccording to claim 2, wherein the porous base material layer includes aporous polyolefin-based resin.
 5. The non-aqueous electrolyte batteryaccording to claim 1, wherein the weight average molecular weight of thevinylidene fluoride polymer is 750,000 or more to less than 1.5 million.6. The non-aqueous electrolyte battery according to claim 1, wherein theair permeability of the porous polymer compound is 300 seconds/100 cc orless.
 7. The non-aqueous electrolyte battery according to claim 1,wherein the electrolytic solution holding layer further includesinorganic particles, and the mass ratio of the vinylidene fluoridepolymer and the inorganic particles, or mass of the vinylidene fluoridepolymer:mass of the inorganic particles is 1:1 to 1:10.
 8. Thenon-aqueous electrolyte battery according to claim 2, wherein the porouspolymer compound is formed by coating a solution containing thevinylidene fluoride polymer dissolved in a first solvent composed of apolar organic solvent on a porous base material and immersing the coatedporous base material in a second solvent, which is compatible with thefirst solvent and is a poor solvent with respect to the vinylidenefluoride polymer.
 9. The non-aqueous electrolyte battery according toclaim 1 comprising a laminated filmed exterior body.
 10. A method ofmanufacturing a non-aqueous electrolyte battery, the method comprising:a step of forming a porous polymer compound on the porous base materialby coating a solution containing a polymer material dissolved in a firstsolvent composed of a polar organic solvent on a porous base material,and immersing the coated porous base material in a second solvent, saidsecond solvent being compatible with the first solvent and being a poorsolvent with respect to the polymer material; a step of manufacturing anelectrode body having a positive electrode, a negative electrode, andthe porous base material on which the porous polymer compound is formed,the porous base material on which the porous polymer compound is formedbeing present between the positive electrode and the negative electrode;and a step of accommodating the electrode body in an exterior body,injecting an electrolytic solution into the exterior body, and thencarrying out heat pressing, said polymer material including a vinylidenefluoride polymer, which is a vinylidene fluoride homopolymer or acopolymer including vinylidene fluoride monomer unit and ahexafluoropropylene monomer unit, the mass composition ratio of themonomer units of the vinylidene fluoride polymer, or vinylidene fluoridemonomer units:hexafluoropropylene monomer units, is 100:0 to 95:5, andthe weight average molecular weight of the vinylidene fluoride polymeris 500,000 or more to less than 1.5 million,
 11. The method ofmanufacturing a non-aqueous electrolyte battery according to claim 10,wherein the first solvent is any one selected from a group consisting ofN-methyl-2-pyrrolidone, γ-butyrolactone, N,N-dimethylacetamide, andN,N-dimethyl sulfoxide and the second solvent is any one selected from agroup consisting of water, ethyl alcohol, and propyl alcohol.
 12. Aninsulating material comprising: a porous polymer compound, wherein theporous polymer compound can hold an electrolytic solution in pores, andcan be swollen by the electrolytic solution, the material of the porouspolymer compound includes a vinylidene fluoride polymer, the vinylidenefluoride polymer is a vinylidene fluoride homopolymer or a copolymerincluding a vinylidene fluoride monomer unit and a hexafluoropropylenemonomer unit, the mass composition ratio of the monomer units of thevinylidene fluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and theweight average molecular weight of the vinylidene fluoride polymer is500,000 or more to less than 1.5 million.
 13. The insulating materialaccording to claim 12 further comprising: a porous base material havingthe porous polymer compound formed on at least one surface.
 14. A methodof manufacturing an insulating material including a porous polymercompound, the method comprising: a step of forming the porous polymercompound by coating a solution containing a polymer material dissolvedin a first solvent composed of a polar organic solvent on a basematerial, and immersing the coated base material in a second solvent,said second solvent being compatible with the first solvent and being apoor solvent with respect to the polymer material, wherein the polymermaterial includes a vinylidene fluoride polymer, the vinylidene fluoridepolymer is a vinylidene fluoride homopolymer or a copolymer including avinylidene fluoride monomer unit and a hexafluoropropylene monomer unit,the mass composition ratio of the monomer units of the vinylidenefluoride polymer, or vinylidene fluoride monomerunits:hexafluoropropylene monomer units, is 100:0 to 95:5, and theweight average molecular weight of the vinylidene fluoride polymer is500,000 or more to less than 1.5 million.
 15. A battery pack comprising:the non-aqueous electrolyte battery according to claim 1; a controllingsection that controls the non-aqueous electrolyte battery; and anexterior that covers the non-aqueous electrolyte battery.
 16. Anelectronic device comprising: the non-aqueous electrolyte batteryaccording to claim 1, wherein electric power is supplied from thenon-aqueous electrolyte battery.
 17. An electromotive vehiclecomprising: the non-aqueous electrolyte battery according to claim 1; aconverting apparatus that receives the supply of electric power from thenon-aqueous electrolyte battery and converts the electric power to adriving force of the electromotive vehicle; and a control apparatus thatcarries out information processing concerning a vehicle control based oninformation concerning the non-aqueous electrolyte battery.
 18. A powerstorage apparatus comprising: the non-aqueous electrolyte batteryaccording to claim 1, wherein electric power is supplied to anelectronic device connected to the non-aqueous electrolyte battery. 19.The power storage apparatus according to claim 18 further comprising: anelectric power information control apparatus that sends and receivessignals to and from other devices through a network, wherein thecharging and discharging control of the non-aqueous electrolyte batteryis carried out based on information received by the electric powerinformation control apparatus.
 20. An electric power system, whereinelectric power is supplied from the non-aqueous electrolyte batteryaccording to claim 1 or electric power is supplied to the non-aqueouselectrolyte battery from a power generating apparatus or an electricpower network.